Product Quality Control to Minimize Defects Using the Six Sigma Method in Labor Intensive Industries

PAIG is a manufacturing company that produces footwear components, especially the upper part, which receives orders only from one of the world's brands and will not be producedif there is no order from the brand. The problem is that the upper quality produced by PAIG in January -November 2023 has a higher defect than the target set by management. This impactedthe high demand for additional materials and became wasteful due to the time-consuming re-production, which ultimately resulted in delays in thedelivery of previously agreed orders. This research aimsto analyzethe quality of products made by PAIG using the Six Sigma methodand reduce the numberof defective products currently occurringin the company. Six Sigma quality control uses the DMAIC (Define, Measure, Analyze, Improve, and Control) stages to determine the characteristics of product defects, factors that cause product defects, and improvements to the factors that cause product defects. By using the DMAIC stage, it is known that the typesof defective products are divided into fourcategories, with the largest category being defective components, while PAIG's sigma level is 4.19, which states that there are only 323 pairsof defective products for every 1 million pairs of upper produced. The analysis of this research shows that PAIG needs a standard operating procedure (SOP) to minimizedefective products in each process.