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COMPANY
Pisang sale Sonia is
founded in 2011. It has
4 employee who help
the production of
Pisang Sale Sonia.
It is located in
Kecamatan Cihideung,
Tasikmalaya
PRODUCT
Pisang Sale Sonia is made from
pisang ambon. It has four different
flavour:
original,
cinnamon,
ngiger, and sambal goang. The
added flavour is advantage or
Pisang Sale Sonia.
It is packed into 250g for each.
Each pisang sale has 1-2cm x 1517cm.
Price from owner is Rp.10.000 and
from reseller is Rp 12.000-15.000
It has approved by National
Health Ministry with Dinkes PIRT No. 2143278010657-18. It also
has certification from MUI West
Jawa with No. LPPOM MUI Jawa
Barat: 0112109357113.
STRUCTURE ORGANIZATION
Worker
Supervisor
1
Owner
and Chief
(Sonia)
Job Desk :
Chief : Organizing and Controling
the supply chain process
Supervisor : Helping the chief in
controling the process of production
Worker 1 : peeling, cutting, and
draining banana
Worker 2 : preparing the batter,
frying, remove its oil, and packaging
Helper : helping the workers and
delivering the product
SIX SIGMA
Six sigma programs seek to reduce the variation in
provess that lead to defects. Defect is simply defined as
component that does not fall within the customers
spesification limits.
The central idea behind Six Sigma is that if you can
measure how many "defects" you have in a process, you
can systematically figure out how to eliminate them and
get as close to "zero defects" as possible.
Six sigmas method employed in a systematic projectoriented fashion through the define, measure, analyze,
improve, and control (DMAIC) cycle.
SIX SIGMA
To achieve Six Sigma Quality, a process must produce no more than
3.4 defects per million opportunities. An "opportunity" is defined as a
chance for nonconformance, or not meeting the required
specifications. This means we need to be nearly flawless in executing
our key processes.
Key Concepts of Six Sigma based on General Electric Philosophy:
DMAIC METODOLOGY
SIX SIGMA
STEPS
DEFINE
PROCESSES
Identify customers and their priorities
Identify a project suitable for Six Sigma efforts based on business
objective as well as customer needs and feedback
Identify CTQs (critical-to-quality characteristics)
MEASURE
ANALYZE
IMPROVE
CONTROL
PROBLEMS
PRODUCT:
The fluctuation of price
Problems occur when there is raising in price of materials. Sonia wouldnt easily increase the price
because the fluctuation but it obviously reduce the profit of owner.
The dried banana is break when frying.
There is no burnt from the frying process. The employee is really careful when frying the banana
although sometimes its break in the process. But the break sale pisang is still eligible for sale. Sonia
sells the break sale pisang with smaller package to the kiosk or warung around her home.
MACHINE :
Problem also occurs because of machine failure, temperature setting not optimal, lack of maintenance,
etc.
HUMAN :
Problems also occurred from the human error such as less experienced, exhausted or less control. The last
factor is from the machine such as
METHODS:
The main problem in producing sale pisang is drying process, such as :
The Banana is easily rotten if drying inapropiately especially in rainy season.
It is really difficult to control the drying process because the technic and machine are still using the
traditional methods.
DAY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
has
lost
arounD
380.000/ month
Rp
Rp
DEFINE (1)
The first step is to define goals to improve the overall process . We create SIPOC
diagram that used to improve an operation process. This diagram also shows the
work flow of 5 elements : Supplier, Input, Process, Output and Customer.
SIPOC Diagram
SUPPLIES
INPUTS
Banana
Sellers
Ambon
Banana
Sonia
PROCESSE
S
Cooking the
Banana
OUTPUTS
COSTUMERS
Sale Pisang
Traditional and
Super Market in
Tasikmalaya
Traditional Market in
Bandung
Smooking Maching
Sonia
Spoon
Others
Stove
Knife
Bamboo Tray
Plastic for wrapping
MEASURE (1)
In this step, we tried to
measure the process and
how its performing.
The next table shows :
The total production in
month is 3.000.000 (gr)
Its total production of
dried banana is 1.190.580
(gr)
The posibble pack is 4762
The percent of defect is
0,79%
MEASURE (2)
One of benefit of Six Sigma thinking is described the performance of a
process in terms of its variablitiy and to compare different processes using
a common metric. This metric is defects per million opportunities (DPMO).
The calculation of Pisang Sale Sonia shows below:
CONTROL
Control means taking action in improvement will gradually reduce the defect of
product. It shows calculation in process improvement by including: the total
defect, percentage of loss, six sigma level, total loss per pack, and total loss in Rp.
99,90
10%
20%
30%
40%
50%
60%
70%
80%
90%
%
942 1.884 2.826 3.768 4.710 5.652 6.594 7.536 8.478 9.411
Current
Total Defect
9.420
Percentage
of Loss
0,79
0,71
0,63
0,55
0,47
0,40
0,32
0,24
0,16
0,08 0,0008
Sig Sixma
Level
4,00
4,00
4,00
4,10
4,10
4,20
4,30
4,40
4,50
4,70
5,90
Total Loss
per Pack
38
34
30
26
23
19
15
11
8
4
1
Total Loss
300.00 260.00 230.00 190.00 150.00 110.00
in Rp.
380.000 340.000
0
0
0
0
0
0 80.000 40.000 10.000
Sonia can gradually reduce the defect from 10% to 99%. Reducing the defect
means gaining the new profit as equal as with the total loss of its defect. If Sonia
eventually succeeded to decrease the number of defect up to 99,9%, She will gain:
total current loss-total loss of 99%= Rp.380.000 Rp. 10.000
= Rp.
370.0000
CONCLUSION
Six Sigma is one of means to measure total defects in production and the sistematically
figure out how to eliminate them as close to "zero-defect (99%)". It then employed in
DMAIC system. We (D)efines the process, (M)easure the defect in process, (A)nalyze the
causes of defect, identify the means to (I)mprove, then calculate the way to (C)ontroling the
maintainance of the improvement.
In Pisang Sale Sonia case, we found that the process is still traditionally. The total
production in month is 3.000.000 (gr). Its total production of dried banana is 1.190.580
(gr). The posibble pack is 4.762. The percent of defect is 0,79%.
The total loss of profit apporoximately Rp.380.000/month because of defect.
We've also found that the main problems is drying process and having the reliable machine
will surely reduce the cause of defect.
Sonia can improve its process of production by having modern smoking machine that will
cost her around Rp.6-7.000.000. It's equal with total loss that Sonia could possibly gain
from two years of having defect.
It can gradually reduce its defect and help Sonia to gain Rp. 370.000/month.
REFERENCES
Gupta, Praveen. (2006). Six Sigma Business
Scorecard, 2nd ed. McGraw-Hill .
Heizer, J and Render, B. (2011). Operations
Management, 10th ed, Global Edition, Pearson.
Jacobs, F.R. and Chase, R.B. (2011). Operations
and Supply Chain Management, 13th ed. Global
Edition, McGraw-Hill.
http://
www.ge.com/en/company/companyinfo/quality/wh
atis.htm
http://www.isixsigma.com/new-lean-six-sigma/