Melele
A n n i s a A i n u n L e s t a r i - 2 9 1 2 3 1 2 7
Dr. Yuanita Handayati, M.S.M
Akbar Adhi Utama, ST., M.A.B.,Ph.D
T e r n a k L e l e b y A n n i s a
Lectuter:
L E A N S I X S I G M A A N D S T A T I S T I C A L Q U A L I T Y C O N T R O L F O R Q U A L I T Y A N D P R O D U C T I V I T Y
I M P R O V E M E N T O F M E L E L E
Table of Content
ANALYZE MEASURE
IMPROVE DEFINE
CONTROL
T
D M A
I C
“Melele, Ternak Lele by Annisa" faces challenges related to the quality and productivity of its catfish farming operations. The current production processes may lack the efficiency required to consistently deliver high-quality catfish, leading to
fluctuations in product quality and potentially impacting
customer satisfaction. Additionally, there might be issues with the overall productivity of the farm, including suboptimal
resource utilization, process variability, and inefficient workflow management.
Bacground
Problem
These challenges highlight the need for a systematic approach to quality and productivity improvement. Implementing Lean Six Sigma and Statistical Quality Control methodologies can address these issues by identifying and eliminating waste,
reducing process variation, and optimizing operational
processes. By applying these principles, "Melele, Ternak Lele by Annisa" aims to enhance both the quality of its catfish products and the overall productivity of its farming operations. This
strategic initiative is crucial for maintaining a competitive edge in the market, ensuring customer satisfaction, and achieving
sustainable business growth.
DEFINE DEFINE DEFINE
(D)
(D) (D)
DEFINE (D)
In 2022, the production defects of type of catfish weighing 400g reached 11% increase. It can be assumed that the condition of minor defects in catfish weighing 400g products is varies, seen from the results of the standard deviation number of defective products. To identify the root cause of these defects, the manager is reviewing the major steps in the fish process also analyzing defect and customer complaint data first.
Supplier Input Process Output Customer
catfish seeds supplier
Catfish Seeds
Prepare Catfish
Seeds Nursery Phase
- Monitor Water Quality
- Stock Catfish Seeds in
Nursery Tanks - Feed with
Specialized Nursery Feed
Growth Phase
- Transfer to Grow -Out Ponds/Tanks - Feed with Grow-Out Feed
- Monitor Water Quality and
Temperature
- Implement Disease Prevention Measures
Harvest Catfish
weighing 400g
Customers directly visit the farm to purchase catfish.
Customer orders catfish over the phone.
FLOWCHART PROCESS OF CATFISH WEIGHING 400G
DEFINE (D)
RECENT MONTH The Number of
Fish Produced 55,000 Catfish Defects 5,500 Catfish Defects Rate 10%
DEFINE (D)
DEFECT AND COSTUMER COMPLAIN DATA
MEASURE MEASURE MEASURE
(M)
(M) (M)
The catfish size, typically weighing 1 kg and containing 2 catfish, has now reduced, resulting in 1 kilogram comprising 3 catfish.
The 100g catfish purchased by the customer for re-cultivation cannot survive for a long time.
The darker color of the catfish has led to customer complaints.
The catfish emit an unpleasant smell.
Defects that have occurred in 2022 based on incoming consumer complaints are:
1.
2.
3.
4.
Defects
MEASURE (M)
MEASURE (M)
After collecting the data, the manager is considering using Defects Per Million Opportunities (DPMO) to measure its Six Sigma level. DPMO is a metric that measures the number of defects per million opportunities for a defect to occur. The manufacturer performs 2 checks to test the quality of the farmed catfish.
Result:
It shown that the DPMO for Farmed Catfish product is 45,455 which means that the fish fillets process is capable of producing 45,455 defective farmed catfish at a sigma of 3.19 using Six Sigma Calculator.
MEASURE (M)
Manager take a look back to defect and customer complaint data, it shows that they received 5000 complaints from customers about its fish farmed catfish. They used a Pareto chart to identify the common defects in its farmed catfish production process and found the following result :
MEASURE (M)
P a r e t o C h a r t
1
2
ANALYZE ANALYZE ANALYZE
(A)
(A) (A)
The customer complaints outlined in the preceding slide prompted the manager to delve further into the issues affecting the catfish farming operation. Utilizing a Cause- Effect Diagram or Fishbone Diagram, they conducted an analysis considering Measurements, Materials, Men, and Environment. This suggests that the observed defects are likely influenced by factors within these four categories.
ANALYZE (A)
ANALYZE (A)
IMPROVE IMPROVE IMPROVE
(I)
(I) (I)
Catfish darkens 46%
Catfish Size 24%
not worth re-cultivating 18%
Catfish Smells 12%
IMPROVEMENT (I)
Based on the information presented earlier, there are 4 defects occurring in "Melele, Ternak Lele by Annisa." The owner has also analyzed the causes of these defects using the "Fish Bone" method. Based on the analysis results, here are the proposed improvements that "Melele, Ternak Lele by Annisa" can undertake for the sustainability of its business:
IMPROVEMENT (I)
24% 48%
Proposal For Improvement
IMPROVEMENT (I)
The catfish size, typically weighing 1 kg and containing 2 catfish, has now reduced, resulting in 1 kilogram comprising 3 catfish.
Measurement
The darker color of the catfish has led to customer complaints.
Materials
Problem
Solution
Problem
Solution
Employ data analytics tools to analyze historical data and identify patterns related to fish growth, feed conversion rates, and other performance metrics. This enables data-driven decision-making for continuous improvement.
Ensure the use of high-quality and nutritionally balanced feed from reputable suppliers.
Regularly assess and verify the nutritional content of the feed to meet the specific requirements of catfish at different growth stages.
18% 12%
Proposal For Improvement
IMPROVEMENT (I)
The 100g catfish purchased by the customer for re-cultivation cannot survive for a long time.
Men
The catfish emit an unpleasant smell
Environment
Problem
Solution
Problem
Solution
Introduce mechanized equipment for tasks like pond aeration, feeding, and harvesting to reduce the manual labor required and improve overall efficiency.
Adopt sustainable pond management practices, including proper pond bottom preparation, to prevent issues like oxygen depletion, nutrient imbalances, and the release of harmful gases.
QONTROL QONTROL QONTROL
(Q)
(Q) (Q)
QONTROL (Q)
CALCULATION OF CAPABILITY PROCESS
In 2022, the manager employed a Control Chart to oversee and manage the quality of products and services; however, the outcomes deviated from the anticipated results.
RESULT : The Cpk 1 shows that process is not capable of producing products within the LSL and USL
QONTROL (Q)
CALCULATION OF UCL & LCL
Manager also calculated the upper and lower control limits (UCL and LCL) in 2022 using control chart limits that leverage the process mean and standard deviation to monitor the stability of their Farmed Catfish producton process
QONTROL (Q)
CONTROL CHART CALCULATION
QONTROL (Q)
CONTROL CHART CALCULATION
QONTROL (Q)
CONTROL CHART CALCULATION
The manager persisted in overseeing the fish quality, anticipating favorable outcomes from the implemented improvements.
Following the enhancements, the P chart analysis indicated that the process exhibited normal behavior, signifying a stable proportion of defective items without notable variation over time. This observation implies that the process is under control, with no discernible special causes impacting output quality.
Furthermore, the pattern consistently falls within the control limits of 0.051 to 0.273, reinforcing the stability of the process.
Conclusion
Conclusion Conclusion
Based on the complaint data, "Melele, Ternak Lele by Annisa" utilized a Cause- Effect Diagram, also known as a Fishbone Diagram, to pinpoint the root cause of defects in their farmed catfish. The diagram categorized potential causes into four groups: Measurements, Materials, Man, and Environment.
Following the identification of the root cause, the company employed improvement initiatives, tailoring specific recommendations for each category to drive enhancements.
Subsequently, the fish fillets company implemented a control chart to assess the UCL and LCL for the period from January to December 2022 after integrating these improvement initiatives. The chart demonstrated that the company successfully maintained the quality of its products within the established UCL and LCL limits post-implementation of the improvements.
