IMPROVING QUALITY IN ATM CARD PRODUCTION AT PT. DEF USING SIX SIGMA METHODOLOGY
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Muhammad Farrel Apta Fedora
The ATM card production process at PT DEF has encountered recurring quality defects, including misaligned printing, uneven cutting, and scratched surfaces, leading to increased costs, operational inefficiencies, and reduced customer satisfaction. These issues have significantly impacted production reliability and raised concerns about the company’s ability to meet industry standards. Given the critical importance of quality in banking products, PT DEF must address these challenges to maintain its reputation, operational efficiency, and customer trust. This research employs the Six Sigma DMAIC framework to identify, analyze, and address the root causes of defects. Data collection methods include Failure Mode and Effects Analysis (FMEA), control charts, and fishbone diagrams, supported by interviews and observations. The study prioritizes corrective actions based on Risk Priority Numbers (RPN) and implements improvements such as equipment upgrades, enhanced training programs, and stricter material quality control. A robust control phase ensures sustainability through monitoring, audits, and real-time reporting. The findings reveal a reduction in defect rates and significant improvements in process efficiency following the implementation of corrective measures. The DPMO decreased from 5,108.38 in June 2022 to 1,881.40 in March 2024, with corresponding improvements in Final Yield and Sigma Values. These results demonstrate the effectiveness of a structured quality management approach in addressing production challenges and underline the importance of sustained efforts to achieve near-perfect production standards in the banking industry.
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