Defect Analysis for HDPE Plastic Bag Products Using Seven Tools Method and mprovement 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.