An Application of Six Sigma to Reduce Defects from the Precast Concreate Processing: a Case Study of Company A

Abstract

Precast concretes are widely used in construction because it can reduce production costs and construction time. However, factories have encountered with the defects resulting from the production of precast concrete process. This research aims to reduce the defects resulting from the precast concrete processing through action research methodology. It includes four phases
1) problem identification 2) action planning 3) tacking action and 4) evaluation. In taking action phase, six sigma methodology was implemented through the collocation between researcher and participants. Six sigma methodology consists of five steps: define, measure, analyze, improve and control (DMAIC). The results showed that before the improvements the sigma level of precast concrete processing was 3.3, after the improvements by developing work standard procedures for precast concrete production and training of staff about purchasing of materials. The number of defects were reduced from 9 to 7 from per 36 pieces of production which accounted for 22.22 percent and the sigma level after the improvements was 3.5. The results of the research shown that the application of Six Sigma as a quality management tool can reduce defects from the precast production process. This research will be useful to plant managers or head of production who want to reduce defects in the production process and reduce production costs.