Implementation of Six Sigma DMAIC Methodology for Eliminating Spot Crack Defects in Automotive Resistance Spot Welding Process
Article Sidebar
Main Article Content
Abstract
Automotive welding processes require high process stability because welding defects directly influence product reliability and manufacturing cost. This study investigates the reduction of spot crack defects in an automotive Rear Door welding process using the Six Sigma DMAIC (Define–Measure–Analyze–Improve–Control) methodology. A quantitative case study approach was applied by integrating defect analysis, process capability measurement, Pareto analysis, Fishbone analysis, and corrective action implementation. The initial assessment identified 20 spot crack defects from 2,400 production units, resulting in a DPMO value of 2,083.33 and a process capability level of 4.37 sigma. Root cause analysis revealed that the defects were mainly associated with insufficient operator knowledge, unstable welding gun positioning due to damaged gun shanks, limited inspection coverage, and the absence of welding position control. Improvement actions included operator retraining, equipment replacement, additional inspection points, and implementation of a welding gun guide fixture. After improvement implementation, monitoring of 2,380 production units showed zero spot crack defects, achieving a DPMO value of 0 and process capability above 6 sigma. The findings demonstrate that a structured Six Sigma DMAIC approach combined with welding-specific process controls can effectively enhance automotive welding quality and support sustainable defect prevention.
Article Details
This work is licensed under a Creative Commons Attribution 4.0 International License.
How to Cite
References
Adi, A. F. (2025). Buku Ajar Manajemen Bisnis Industri. Global Kreatif Media. https://books.google.co.id/books?id=W8aFEQAAQBAJ
Adji, W. N. (2022). Pengendalian Kualitas Proses Produksi Konveksi pada PT Kaosta Sukses Mulia. Jurnal Ilmiah Manajemen & Kewirausahaan, 9(1), 67–80.
Annas, M. (2025). BAB 10: Six Sigma. In Manajemen Kualitas: Konsep, Strategi, dan Implementasi (p. 162).
Baldah, N. (2020). Analisis Tingkat Kecacatan dengan Metode Six Sigma pada Line TGSW. EKOMABIS: Jurnal Ekonomi Manajemen Bisnis, 1(1), 27–44. https://doi.org/10.37366/ekomabis.v1i01.4
Fadhilah, N., Hasibuan, A., Ahmadi, A., Harahap, D. N., & Ritonga, K. (2023). Memperkuat Posisi Daya Saing Perusahaan. Journal of Management and Creative Business, 1(1), 79–85.
Fonna, N. (2019). Pengembangan Revolusi Industri 4.0 dalam Berbagai Bidang. Guepedia. https://books.google.co.id/books?id=j8KZDwAAQBAJ
Gaspersz, V. (2007). Lean Six Sigma. Gramedia Pustaka Utama.
Hariyanto, D. M., Pradita, R., Jaya, R., Yanuardi, F. V, & Nur, A. (2025). Pengaruh Alokasi Biaya Produksi, Skala Ekonomi, dan Inovasi Produk terhadap Profitabilitas Perusahaan Manufaktur. Journal ANC, 1(3), 212–222.
Hikmah, W. R., Wijaya, J. A., Hidayah, A. A., Syaputra, R. A., & Abdullah, M. (2024). Perspektif Kepuasan Pelanggan PT. Arrazi Ghirah Medika: Peran Fundamental Kualitas Produk dan Kualitas Pelayanan dalam Mewujudkannya. Manajemen: Jurnal Ekonomi, 6(1), 42–54.
Irwanto, A., Arifin, D., & Arifin, Moh. M. (2020). Peningkatan Kualitas Produk Gearbox dengan Pendekatan DMAIC Six Sigma pada PT. X, Y, Z. Jurnal KaLIBRASI: Karya Lintas Ilmu Bidang Rekayasa Arsitektur, Sipil, Industri, 3(1), 1–17. https://doi.org/10.37721/kalibrasi.v3i1.638
Jirasukprasert, P., Garza-Reyes, J. A., Kumar, V., & Lim, M. K. (2014). A Six Sigma and DMAIC Application for the Reduction of Defects in a Rubber Gloves Manufacturing Process. International Journal of Lean Six Sigma, 5(1), 2–21. https://doi.org/10.1108/IJLSS-03-2013-0020
Khamaludin, Respatiningsih, I., & Kustiawan, B. (2024). Manajemen Mutu. PT Sonpedia Publishing Indonesia.
Khofifah, A. N. (2024). Analisis Pengendalian Kualitas Menggunakan Metode Six Sigma dan TRIZ Guna Mengurangi Produk Defect (Studi Kasus pada CV. Karya Wahana Sentosa).
Kurnia, H., Jaqin, C., Purba, H. H., & Setiawan, I. (2022). Implementation of the DMAIC Approach for Quality Improvement at the Elastic Tape Industry. J@TI Undip: Jurnal Teknik Industri, 17(1), 40–51. https://doi.org/10.14710/jati.17.1.40-51
Mittal, A., Gupta, P., Kumar, V., Owad, A. Al, Mahlawat, S., & Singh, S. (2023). The Performance Improvement Analysis Using Six Sigma DMAIC Methodology: A Case Study on Indian Manufacturing Company. Heliyon, 9(3), e14625. https://doi.org/10.1016/j.heliyon.2023.e14625
Nakhai, B., & Neves, J. S. (2009). The Challenges of Six Sigma in Improving Service Quality. International Journal of Quality & Reliability Management, 26(7), 663–684. https://doi.org/10.1108/02656710910975741
Nazia, S., Fuad, M., & Safrizal. (2023). Peranan Statistical Quality Control (SQC) dalam Pengendalian Kualitas: Studi Literatur. Jurnal Mahasiswa Akuntansi Samudra, 4(3), 125–138. https://doi.org/10.33059/jmas.v4i3.8079
Nirfison, & Soesilo, R. (2022). Analisis Cacat pada Pemasangan Gasket di Lini Assembly dengan Pendekatan DMAIC Six Sigma. Jurnal Taguchi, 2(1), 1–12.
Putri, N. T. (2022). Manajemen Kualitas Terpadu: Konsep, Alat dan Teknik, Aplikasi. Indomedia Pustaka.
Rifka, R. N. (2017). Step by Step Lancar Membuat SOP. Penerbit Nauli Media.
Sahelangi, M. M., & Wulandari, L. M. C. (2023). Analisa Pengendalian Kualitas Menggunakan Metode Six Sigma pada Kemasan Produk X di PT GF. JISO: Journal of Industrial and Systems Optimization, 6(1), 1–8.
Sihombing, M. I. S., & Sumartini. (2017). Pengaruh Pengendalian Kualitas Bahan Baku dan Pengendalian Kualitas Proses Produksi terhadap Kuantitas Produk Cacat dan Dampaknya pada Biaya Kualitas (Cost of Quality). Jurnal Ilmu Manajemen Dan Bisnis, 8(2), 42–49.
Sirine, H., & Kurniawati, E. P. (2017). Pengendalian Kualitas Menggunakan Metode Six Sigma (Studi Kasus pada PT Diras Concept Sukoharjo). Asian Journal of Innovation and Entrepreneurship, 2(3), 254–290.
Supriyati, & Hasbullah. (2020). Analisis Cacat Painting Komponen Automotive dengan Pendekatan DMAIC-FMEA. Operations Excellence: Journal of Applied Industrial Engineering, 12(1), 104–116. https://doi.org/10.22441/oe.2020.v12.i1.009
Suryatman, T. H., Kosim, M. E., & Julaeha, S. (2020). Pengendalian Kualitas Produksi Roma Sandwich Menggunakan Metode Statistik Quality Control (SQC) dalam Upaya Menurunkan Reject di Bagian Packing. Journal Industrial Manufacturing, 5(1), 1–12. https://doi.org/10.31000/jim.v5i1.2429
Tripalupi, L. E., Nuridja, M., & Yuliasih, N. K. (2014). Analisis Pengendalian Kualitas Produk pada Perusahaan Garmen Wana Sari Tahun 2013. Jurnal Jurusan Pendidikan Ekonomi Undiksha, 4(1).
Wulandari, I., & Bernik, M. (2018). Penerapan Metode Pengendalian Kualitas Six Sigma pada Heyjacker Company. EkBis: Jurnal Ekonomi Dan Bisnis, 1(2), 222–241.