Defect Analysis for HDPE Plastic Bag Products Using Seven Tools Method and Improvement Strategy with Kaizen Method at PT. HSKU

Abstract

PT. Harapan Sejahtera Karya Utama (HSKU) is a manufacturing company engaged in the production of plastic bags. This company produces various types of plastic bags made from HDPE. One of its superior products is HDPE plastic bags measuring 15x30, with total production from July to December 2022 of 3,072,923 units and a total of 435,670 units of defects. The purpose of this study is to determine the percentage of defects and their causes of defects and to propose quality improvements. This study uses the Seven Tools and Kaizen methods. The results of the study show that the percentage of defects in HDPE plastic bag products measuring 15x30 has the highest defects, namely Hole Defects at 64.76%; Folded Defects at 22.76%; Dirty Defects at 7.45%; and Detached Seal Defects at 5.03%. Proposed improvements are given with the Kaizen method, namely conducting supervision and controlling the five M factors and the five-step plan, namely providing training to improve operator capabilities and refreshments (SOP), applying strict penalties when making mistakes repeatedly, and making machine grouping data. According to the type and function, placing procedure manuals around the machine area, arranging air circulation equipment as needed, and providing storage areas for materials and plastic rolls in a safe and sterile place.