"Enhancing Process Reliability Through Six Sigma DMAIC Approach in The Flexible Packaging Manufacturing Sector: A Case Analysis"

This project work aims to provide a better way to improve reliability of process in a print pack material industry. As of requirement for effective as well as efficient manufacturing methods increases throughout the world, manufacturing firms lean towards robust approaches to acquire their way to Operation Excellence in product and service quality. This study concentrated on the Define-Measure-Analyze-Improve-Control approach for exploring the root causes of slitting department, and to offer a better way to the improvement of overall work procedure. In the data gathering stage, the lowest performing machines are selected, next to quantitative and qualitative process examination to recognize the possible reason(s) which were responsible for the low process reliability of machines’. Statistical examination methods were selected for the authentication of possible reasons that will impact machine(s) performance critically. The study specifies in data context the real MPM of operation of the slitting machine was less than the standard MPM due to the probability of getting slipped roll after slitting, and the existence of tags on within the laminated roll. These factors contribute in 15% – 35% of the overall non-operating time. Workers’ capability to see non-operating time was also examined among possible factors that can affect the working performance of slitting machines. After applying improvement techniques, there was an improvement in process reliability by keeping standard quality level for each product.