Analysis of Carton Packaging Quality Control Using Statistical Quality Control Methods at PT XYZ
Analysis of Carton Packaging Quality Control Using Statistical Quality Control Methods at PT XYZ
Abstract:-This research focuses on analyzing the quality costs, namely quality control costs, and the level of product
control of cardboard box packaging at PT XYZ using the damage produced is very low or only a few damaged
Seven Tools method. The main problem faced by the products occur. Quality is one of the important dimensions in
company is the high level of defects in the cardboard box products and processes, this will show the competitive
products produced, which has a negative impact on advantage of a company versus other companies
production efficiency and customer satisfaction. The aim (Zonnenshain & Kennet, 2020)[1]
of this research is to analyze the main causes of defects in
cardboard box products and provide suggestions for The business world is becoming more competitive in
improvements that can be implemented by companies. the modern era. Competition is not limited to the domestic
The method used in this research is Statistical Quality market; it is now on the global stage. Any company operating
Control (SQC) which involves the use of Seven Tools, in a highly competitive market must constantly compete with
namely check sheets, Pareto charts, fishbone diagrams other businesses operating in the same sector. All company
and control charts. Using these tools, data regarding tactics and strategies to maintain competitiveness and survive
defects is collected, analyzed, and interpreted to identify in worldwide competition with other companies' products
the main causal factors of quality problems. The analysis have been influenced by quality difficulties (La Hatani, 2007)
results show that certain factors, such as the quality of [2], good quality results from good processes and meets
raw materials, production processes, and operator skills, standards that have been determined based on market needs.
have a significant contribution to the occurrence of A company located in Cikarang, West Java. This company
defects. Based on these findings, this research proposes operates in the logistics, export and import business sectors.
several improvements that can be implemented by PT Company XYZ involves strategic aspects other than standard
XYZ to improve the quality of their cardboard box logistics which include transportation, warehousing,
products. Proposed improvements include increasing packaging and distribution processes and logistics
control over the quality of raw materials, skills training information. One of the advantages of the product is the
for operators, and implementing stricter standard packaging, the appearance of the packaging meets shipping
operational procedures in the production process. By standards for export. However, the packaging process cannot
implementing this proposed improvement, it is hoped that be separated from problems or NG (Not Good) products,
PT XYZ can reduce the level of defects in their products, including dirty, torn and dented products. To analyze the
increase production efficiency, and increase customer factors causing the existence of these NG products, quality
satisfaction. control is needed. The strategy that can be used to control
product quality in each preparation is a factual control
Keywords:- Quality Control, Defect, Seven Tools, Statistical strategy or what is usually called Statistical Quality Control
Quality Control, Why Why Analysis, Improvement Proposals. (SQC), which is a framework created to maintain production
quality measures, at least at a level that uses measurable
I. INTRODUCTION strategies to analyze information.
Quality control must be able to direct several goals in an From packaging data for the last 3 months, Deefct that
integrated manner, so that consumers can be satisfied using has been produced on the packaging line from total
the company's products or services. Quality control is an production is 3125 pcs with a gross defect presentation of
activity that is often carried out by every company. If quality 6.08%, dents of 4.38% and tears of 9.89%.
control is carried out well, the company will incur additional
The results of Figure 1 show the number of defects for The process of controlling production in terms of both quality
the period April - June 2023, as well as the types of defects and quantity is an extremely significant activity in a
that occur in Figure 1. The most common defects shown in company. This activity should be as economical or as low as
the Pareto diagram are tear defects. From the overall feasible. As stated in the article (Assauri, 2008:299) [5], the
production results, this is not a small number, therefore there objectives of quality control are:
must be improvements and quality control to reduce the
presentation of defects. Production goods are able to meet the specified quality
requirements.
II. LITERATURE REVIEW Try to minimize inspection costs.
Make efforts to minimize the design costs of goods and
Quality procedures that use certain manufacturing attributes.
Quality is the main factor in determining whether Strive to keep production costs as low as possible.
consumers subscribe to the product. Customers will feel Determining the extent to which the process and output of
satisfied if the product provided is of high quality and meets a good or service complies with the standards set by the
their needs. According to (Assauri 2016:317) [3], When company is the main objective of quality control. The
qualities are prioritized to meet the wants and desires of following are general quality control objectives as stated
customers, the emphasis is on those attributes. explains that by (Heizer & Render, 2013) [6]are as follows:
quality is a dynamic state that affects environments, people,
processes, goods, and services that meet or exceed To ensure that the finished product meets the quality
expectations. The American Society for Quality defines it as standards that have been set.
the general qualities and attributes of a good or service that To allow for efficient expenses associated with product
can meet specific or general demands. Thus, the business design, inspection, and production.
makes a constant effort to uphold the caliber of its output in The fundamental tenet of quality control is that processes
order to consistently provide high-quality goods and sustain must be continuously achieved and improved in order to
customer happiness. (2011) Heizer and Render[4] generate data that can be utilized for process control and
improvement, enabling the process to meet customer-
Quality Control Objectives desired product specifications. Therefore, the primary
The primary objective of quality control is to ensure goal of quality control is to ensure that the produced good
that the quality of the goods and services that are or service satisfies the established requirements for
manufactured does not fall short of the quality standards that quality while incurring the fewest feasible expenses..
have been established at a cost that has also been established.
Factors that Influence Product Quality According to (Nasution 2017:39) [9], The statistical
According to (Assauri, 2015:362) [7]there are 9 general approach known as statistical quality control (SQC) is a
factors that influence quality which are commonly known as technique that applies probability theory to the process of
9M, namely: testing or analyzing samples. Quality assurance and control
procedures for the product. In acquainted with (Sumayang
Market (Market) 2007:272) [10] Quality control known as Statistical Quality
Money (Money) Control (SQC) makes use of basic statistics to find and
Management (Management) remove variations that are not random or that arise just once
Men (Human) throughout the manufacturing process. With the tools
Motivation (Motivation) included in SQC, quality control may be performed
Material, Machine and Mechanization (Materials, statistically. According to Heizer and Render (2006),
Machines and Mechanization) statistical quality control is a procedure used to uphold
Modern information method (Information methods and standards, measure, and address issues with manufactured
mechanisms) goods or services. [11]In addition to monitoring the process
and quality of the products being worked on, statistical
Mounting product requirements (production process
quality recognition can be used to approve or reject goods
requirements)
that have been made.
Dimensions of quality
The theoretical framework used in this research shows
According to (David Garvin 1987) [8], determining the
how statistical quality control can help in assessing the level
dimensions of product quality can be done through eight
of damage to cardboard packaging, determining the reasons
dimensions, namely performance, features, reliability,
behind it, and then investigating potential improvements to
suitability, durability, service ability, aesthetics, image or
the problem to produce suggestions or recommendations for
reputation.
improving production. quality going forward.
Performance (Performance), the extent to which a product
III. RESEARCH METHODS
or service fulfills its function as expected.
Features, additional characteristics that complement the Research Design
basic function of a product or service. In particular, systematic scientific research on
Reliability, the ability of a product or service to function components and phenomena as well as the cause and effect
properly during a certain period. correlations of these interactions is used in this study as a
Conformance (suitability), the extent to which a product form of quantitative research. The methodical study of
or service meets certain specifications or standards. phenomena through the collection of quantifiable data by
Durability, the product's lifespan or the ability of the statistical, mathematical, or computer methods is known as
product to continue to be used before it needs to be quantitative research. The quantitative research techniques
replaced. put forward by (Sugiyono 2009: 14) [12] may be seen as a
Serviceability (Ease of Repair), ease and speed in research method that is founded on the philosophy of
repairing products or services. positivism and is utilized for the purpose of conducting
Aesthetics, the look, feel, sound, smell, or other sensory research on specific populations or samples. The various
impression of a product or service. sampling approaches are typically carried out in a random
Perceived Quality, the general impression that consumers fashion, research tools are utilized for data collecting, and
have about product quality quantitative and statistical analysis is performed with the
intention of testing hypotheses.
Understanding Statistical Quality Control
Statistics is a decision making tool that involves the Data Collection Methods
process or analysis of information contained in a sample. In In research, data collection techniques are an important
quality assurance, statistical methods play an important role . factor for the success of the research. This relates to how to
This is a system developed to maintain production quality collect data, who the source is, and the method used. The
standards at minimum costs, using statistical methods to type of data used in this research is divided into two, namely:
collect and analyze data. Statistical Quality Control (SQC), in
which the quality of the production process is managed Primary data is data obtained from direct observations in
beginning with the beginning of production, continuing the field. The primary data required for the investigation
through the manufacturing process, and ending with the final of XYZ company is as follows:
product, is a method that is utilized for the purpose of
controlling and managing the items that are created. Before The method of documenting organized patterns in the
the product is released to the market, it is first subjected to an actions of subjects (individuals), things, or occasions
inspection, during which the items that have been without speaking to or interrogating the subject. Pay close
manufactured are split into two categories: those that are of attention to the procedure of packing the product.
high quality and those that are not. Interview. The data collection technique in the research
method uses verbal questions to investigate a topic.
Interviews can be done directly via telephone.
Pareto Chart
In order to make it easy to read or explain data quickly, the data needs to be presented in the form of a Parerto diagram which
is a visual data presentation tool in the form of block graphics that pays attention to the distribution of the values obtained in the
form of numbers.[14]
n : Number checked
LCL + P – 3
Calculating the center line (CL)
Information:
∑𝑛𝑃
∑𝑛 𝑝̅ : Average damage to cardboard boxes
Based on Table 3 , it is known that during observations defects in the cardboard box packaging process. The four
from April to June the production amount was 3125 pcs with statistical analysis tools are as follows:
a total of 636 defective pcs.
Cheek Sheet
Statistical Quality Control Method The first stage in quality control analysis to create a cheek
In research using Statistical Quality Control, statistical sheet or inspection sheet is to compile a table containing
analysis tools will be used, namely check sheets, Pareto columns for date, production quantity, type of damage and
diagrams, control charts and fishbone diagrams. The use of number of defects. The results of data collection via cheek
these four tools is considered to have met the research sheets which were carried out over the 3 month period April
objectives, namely to determine the factors that cause product – June 2023 can be seen in Table 2 below.
Based on Table 2 of the cheek sheet above, it can be on the cheek sheet, it was found that the total packaging for
seen that the number of cardboard box packaging production the period April – June 2023 was 3,125 pcs with a total of
in April 2023 is 1,125 pcs with gross defects of 58 pcs, 40 190 gross defects, 137 pcs dented and 309 pcs torn.
pcs of dents and 93 pcs of tears. In May PT. XYZ produces
cardboard box packaging with a total production of 1000 pcs Pareto Chart
with details of gross product defects of 44 pcs, 34 pcs of After the cheek sheet, the next step is to create a Pareto
dents and 93 pcs of tears. In June PT. XYZ produces 900 pcs diagram. This Pareto diagram is useful for seeing the types of
of cardboard box packaging with details of gross product damage that occur most frequently.
defects of 88 pcs, 63 pcs of dents and 138 pcs of tears. Based
Based on the Pareto diagram above, we can see that the not. As previously discussed, the initial steps in creating a
type of damage that occurs most frequently is tearing, with a control chart are as follows:
total of 309 damages.
Calculate the damage percentage.
Control Chart Calculating the central line (CL).
After making a check sheet and Pareto diagram, the Calculating the Upper Control Limit (UCL).
next step is to make a control chart which functions to see Calculating the Lower Control Limit (LCL).
whether quality control in this company is under control or
As a rule of thumb (Prawirosentono, 2002) [15], the display the possible causes of a particular effect. Fishbone
following criteria are used: diagrams are used when causes are grouped naturally based
on the categories of materials, methods, equipment,
Determine the reason if P < LCL, which indicates that all environment and people.
samples are in the receiving region (LCL).
Samples are considered to act normally or have adequate The first and most important are workers, namely workers
processing capability if LCL <P> UCL, which indicates who are actively involved in industrial processes.
that all samples are in the receiving region. The components used in the process of making a product
If P > UCL, it indicates that the sample has jumped into finished goods, are also called raw materials.
outside of the reception area (UCL) or that the process Equipment, also called tools, consists of various tools
capability is inadequate. Investigate the reasons and used during the production process.
improve performance in the production process activities Method, namely instructions for the manufacturing
to address the issue. process or work orders that must be obeyed
Because P is above the UCL limit, the process Environment, namely the conditions around the
capability is not running well, so the cause must be production site, which have an impact on the production
process, both directly and indirectly.
checked and corrective action taken by increasing
performance in production process activities. We can see in Figure 5, namely the Pareto product
diagram where there are three types of defects that arise in
Fishbone Diagram the production process, namely dirty, dented and torn. As a
tool to find the cause of the damage, a fishbone diagram is
A cause – effect diagram also known as an Ishikawa or
used to determine the type of damage.
“fishbone” diagram is a graphical tool used to explore and
Factors that Become Obstacles and Causes of Product causes based on the 80/20 principle, and control charts to
Defects control processes statistically, could provide important
initial insights. Why-Why Analysis deepens
Why-Why Analysis is a systematic approach to understanding of the cause-and-effect sequence involved
identifying the root cause of a problem by asking in problems, enabling the implementation of more
successive "why" questions until reaching the underlying targeted and effective corrective actions in an effort to
root. Previously, the use of tools such as check sheets for improve process quality and efficiency.
data collection, Pareto diagrams to highlight the main
Improvements
After knowing the causes of deviations that result in defects in cardboard box products, a proposal for general corrective
action is prepared in an effort to reduce the level of product defects.
Table 4 Improvements
No Sumber Penyebab Faktor Penyebab Improvement
1 Man 1. Workers do not comply with the SOP. 1.Training and counseling.
2 Method 1. It is necessary to adjust the SOP to actual conditions. 1. Changes to WI and SOP.
3 Environment 1.Limited packaging operator layout. 1.Layout settings.
Based on the results of analysis through control charts, [6]. WW Huler, AHJ Fanggidae, NP Nursiani, CC
it can be concluded that the cardboard box packaging Feonay, and P. Management, "ANALYSIS OF
production process at PT. XYZ is not good, so the process QUALITY CONTROL ON PINK JAYA TOFU
capability is not running well, so the cause must be checked PRODUCTS IN THE CITY OF KUPANG-NTT
and corrective action taken by increasing performance in Analysis Of Quality Control On Pink Jaya Tofu
production process activities. Furthermore, it can be seen in Products In The City Of Kupang-NTT
the fishbone diagram and Why Why Analysis, the main cause Correspondence : a).”
of product defects is the human factor where humans/workers [7]. G. Vanny Maruli Tua and and Ira Meike Andariyani,
do not carry out the SOP that has been created, the method "THE INFLUENCE OF PRODUCT QUALITY AND
requires adapting the SOP to actual conditions and an PRICE ON THE DECISION TO PURCHASE A
unclean work environment and layout. limited. DAB DECKER SUBMERSIBLE WATER PUMP
MACHINE AT CV. CITRA NAULI
V. CONCLUSION ELECTRICSINDO PEKANBARU," vol. 1, no. 4,
2022.
Based on the Pareto diagram created, it can be seen that [8]. D. Puspitasari, S. Surjani, T. Politeknik, and N.
the highest defect level is torn defects with a total of 309 Bandung, "The Influence of kartuHALO Product
pcs with a percentage of (9.89%). The second highest Quality on User Satisfaction (Study at GraPARI
defect rate was gross with a total of 190 pcs with a Telkomsel MTC Bandung)," 2016.
percentage of (6.08%). And the lowest defect level below [9]. MS Arianti, E. Rahmawati, DRRY Prihatiningrum, )
the standard set by the company at 5% is dent defects Magister, and A. Bisnis, "ANALYSIS OF PRODUCT
with a total of 137 pcs with a percentage of (4.38%). QUALITY CONTROL USING STATISTICAL
Meanwhile, the total defects during the three month QUALITY CONTROL (SQC) AT THE AMPLANG
period from April to June were 636 pcs out of a total KARYA BAHARI BUSINESS IN SAMARINDA,"
production of 3125 pcs. 2020.
From the results of the control chart , the process [10]. A. BUSYAIRI, "STATISTICAL QUALITY
capability is not running well, so the cause must be CONTROL (SQC) IN DETERMINING THE LEVEL
checked and corrective action taken by increasing OF PRODUCT DAMAGE IN THE 'JAYA ABADI'
performance in production process activities. there is a SASAMBO BATIK HANDICRAFT INDUSTRY IN
need for quality control. This is an indication that the THE VILLAGE OF PRINGASELA-LEMBOK EAST
process is not running well. BUSYAIRI, AHMAD," 2017.
Based on the results of the fishbone diagram analysis and [11]. Rasolofomanana Anjasoa Volahasina, “ANALYSIS
Why - Why Analysis, it can be seen that the factor that OF QUALITY CONTROL OF TILE PRODUCTS
causes the most damage or defects is tearing products in USING STATISTICAL PROCESS CONTROL
the packaging process, which comes from human factors (SPC) AT UD. GENTENG JAYA AMBULU
(workers), work methods, and materials DISTRICT JEMBER THE ANALYSIS OF
QUALITY CONTROL PRODUCT OF ROOF TILE
REFERENCES USING STATISTICAL PROCESS CONTROL AT
CV. GENTENG JAYA AMBULU DISTRICT OF
[1]. A. Asnah and D. Sari, "Introduction to Macro JEMBER," 2016.
Economics," SSRN Electronic Journal , Feb. 2021, [12]. DS Azhari, M. Kustati, and N. Sepriyanti, "Zihnil
doi: 10.2139/ssrn.3786438. Afif, Devi Syukri Azhari, Martin Kustati, Nana
[2]. J. Management et al. , “STATISTICAL PROCESS Sepriyanti," 2023.
CONTROL (SPC) FOR QUALITY CONTROL OF [13]. S. Nazia, M. Fuad, and S. Safrizal, "Statistical Quality
FURNITURE PRODUCTS AT UD. IHTIAR JAYA," Control (SQC) Analysis in Controlling Product
Bisma: Journal of Management , vol. 6, no. 1, 2020. Quality in Brick Businesses in Langsa City," Minfo
[3]. Nuraeni m. Dan Munawarah, "The Influence of Polgan Journal , vol. 12, no. 1, pp. 1404–1416, Jul.
Quality Costs on Damaged Products (Case Study in 2023, doi: 10.33395/jmp.v12i1.12790.
the Radar West Sulawesi Newspaper) Polewali [14]. Irwati Dwi and D. Indra Prasetya, "Reducing Color
Mandar Regency," 2018. Out Defects Using the Seven Tools Approach: Case
[4]. BN Hakim and B. Purwoko, "PRODUCT Study of the Coloring Compound Plastic Industry,"
DEVELOPMENT STRATEGY TOWARDS 2020.
CUSTOMER LOYALTY THROUGH BRAND [15]. WA Balol, "ANALYSIS OF PRODUCTION
EQUITY AND BRAND IMAGE," vol. 3, no. 3, PROCESS QUALITY CONTROL USING THE SIX
2019. SIGMA METHOD AT PTYZ PASURUAN."
[5]. E. Suprianto, "PRODUCTION QUALITY
CONTROL USING STATISTICAL TOOLS
(SEVEN TOOLS) IN AN EFFORT TO REDUCE
THE LEVEL OF PRODUCT DAMAGE," 2016.