The Results of the Application of Lean Six Sigma with the PDCA Method

Oct 13, 2025 by vinooalluri.com 126 views

The Application of Lean Six Sigma to Minimize Waste at the Biscuit Factory with the PDCA Method

In today's increasingly competitive industrial world, manufacturing companies are required to maintain the consistency of the production process. Factors that are inefficient and effective in the production process need to be anticipated so that companies do not require large costs in manufacturing products. To create the quality of the production process in accordance with established standards, companies need to implement a good quality control system.

The Challenge of Waste in the Biscuit Production Process

PT. Asia Sakti Wahid Foods, for example, faces challenges in operational efficiency due to waste that occurs in the biscuit production process. Product defects fluctuating degrees between 20.27% to 34.78%, far above the company's target below 10%. This high level of waste not only affects the company's productivity but also leads to significant financial losses. To overcome this problem, researchers applied Lean Six Sigma with the PDCA method to improve the quality of the production process.

Lean Six Sigma and PDCA Method: A Solution to Improve Efficiency

Lean Six Sigma is a methodology that combines the principles of Lean Manufacturing and Six Sigma to identify and eliminate waste (waste) in the production process. The PDCA method (Plan, DO, Check, ACT) is a structured cycle that helps in implementing changes and gradual improvements. By combining these two methodologies, companies can achieve significant improvements in efficiency and quality.

The Application of Lean Six Sigma with the PDCA Method at PT. Asia Sakti Wahid Foods

In the application of Lean Six Sigma with the PDCA method at PT. Asia Sakti Wahid Foods, researchers took a series of steps:

1. Planning (Plan)

Identification of the problem: Identifying and analyzing the source of waste (waste) in the biscuit production process, such as waiting time, unnecessary processes, and product defects.
Determine the target: Set a clear target to reduce the product defect level below 10%.
Choosing a solution: Choosing the right solution based on the root cause of the cause and involving the team to develop the action plan.

2. Implementation (DO)

Implementation of Solution: Implementing an action plan that has been made by involving the entire production team.
Monitoring: Monitor the implementation of solutions and collect data to evaluate its effectiveness.

3. Examination (Check)

Data Analysis: Analyze the data collected to measure the effectiveness of solutions and identify areas that need to be improved.
Evaluation: Evaluate the results obtained and compare them with the targets set.

4. Action (Act)

Standardization: Applying a successful solution as a new standard for the production process.
Continuous improvement: Identify opportunities to continue to improve product efficiency and quality.

The Results of the Application of Lean Six Sigma with the PDCA Method

The application of Lean Six Sigma with the PDCA method at PT. Asia Sakti Wahid Foods succeeded in giving positive results:

Reduction of Production Time: The number of activities in the biscuit production process is reduced to 21 activities, with a reduction in production time for up to 44 minutes.
Increased efficiency: The company's sigma value increased to 3.67, showing a significant increase in the efficiency of the production process.
Increasing the efficiency of the process cycle: The efficiency of the process cycle increased to 87.36%, showing a more effective increase in production capabilities.
Increased process speed: Process speed increased to 0.0028 processes per hour, showing an increase in the company's ability to produce faster products.

Conclusion

The application of Lean Six Sigma with the PDCA method provides significant benefits for PT. Asia Sakti Wahid Foods in increasing the efficiency and quality of the biscuit production process. Reduction of waste, increasing sigma values, and increasing the efficiency of the process cycle proves the effectiveness of this methodology in creating a more effective and efficient production process. Companies can take advantage of these results to continue to improve product quality and improve competitiveness in the market.

Recommendations for Future Research

Based on the results of this study, the following recommendations are made for future research:

Further application of Lean Six Sigma: The application of Lean Six Sigma with the PDCA method should be further applied to other production processes to achieve similar results.
Continuous improvement: Continuous improvement of the production process should be implemented to maintain the efficiency and quality of the production process.
Training and development: Training and development programs should be implemented to improve the skills and knowledge of production staff to achieve better results.

By following these recommendations, companies can achieve significant improvements in efficiency and quality, and maintain their competitiveness in the market.
Frequently Asked Questions (FAQs) about the Application of Lean Six Sigma with the PDCA Method

In this article, we will answer some of the frequently asked questions (FAQs) about the application of Lean Six Sigma with the PDCA method in the biscuit factory.

Q: What is Lean Six Sigma?

A: Lean Six Sigma is a methodology that combines the principles of Lean Manufacturing and Six Sigma to identify and eliminate waste (waste) in the production process. It aims to improve the efficiency and quality of the production process by reducing defects and variations.

Q: What is the PDCA method?

A: The PDCA method (Plan, DO, Check, ACT) is a structured cycle that helps in implementing changes and gradual improvements. It consists of four stages: planning, implementation, examination, and action.

Q: How does the PDCA method work?

A: The PDCA method works as follows:

Plan: Identify the problem, determine the target, and choose a solution.
DO: Implement the solution and monitor its effectiveness.
Check: Analyze the data collected and evaluate the results.
ACT: Standardize the successful solution and identify opportunities for continuous improvement.

Q: What are the benefits of applying Lean Six Sigma with the PDCA method?

A: The benefits of applying Lean Six Sigma with the PDCA method include:

Reduced waste: Elimination of waste (waste) in the production process.
Increased efficiency: Improved efficiency and productivity.
Improved quality: Reduced defects and variations.
Increased competitiveness: Improved competitiveness in the market.

Q: How can companies apply Lean Six Sigma with the PDCA method?

A: Companies can apply Lean Six Sigma with the PDCA method by:

Identifying the problem: Identifying the source of waste (waste) in the production process.
Determining the target: Setting a clear target to reduce waste (waste) and improve efficiency.
Choosing a solution: Choosing the right solution based on the root cause of the problem.
Implementing the solution: Implementing the solution and monitoring its effectiveness.
Analyzing the data: Analyzing the data collected and evaluating the results.
Standardizing the solution: Standardizing the successful solution and identifying opportunities for continuous improvement.

Q: What are the challenges of applying Lean Six Sigma with the PDCA method?

A: The challenges of applying Lean Six Sigma with the PDCA method include:

Resistance to change: Resistance to change from employees and management.
Lack of resources: Lack of resources and budget to implement the solution.
Complexity: Complexity of the production process and difficulty in identifying the root cause of the problem.
Time-consuming: Time-consuming process of implementing and evaluating the solution.

Q: How can companies overcome the challenges of applying Lean Six Sigma with the PDCA method?

A: Companies can overcome the challenges of applying Lean Six Sigma with the PDCA method by:

Providing training and development: Providing training and development programs to employees and management.
Allocating resources: Allocating resources and budget to implement the solution.
Simplifying the process: Simplifying the production process and identifying the root cause of the problem.
Monitoring progress: Monitoring progress and evaluating the results.

By understanding the FAQs about the application of Lean Six Sigma with the PDCA method, companies can better implement this methodology and achieve significant improvements in efficiency and quality.