Upaya Penurunan Kecacatan Produk Proses Blow Molding pada Industri Kemasan PT. X

Abstract

PT. X produces plastic packaging through Injection and Blow Molding
processes and faces demands to reduce costs due to high defect rates in the Blow Molding process, which impact profits. Defects exceeding a 2% tolerance limit prompted research to find solutions using ABC Classification, Pareto Chart, and 5 WHYS analysis. The research involves analyzing data and field observations, identifying high-production-rate products using ABC Classification, analyzing frequent defects, using a Pareto Chart to identify critical defects, and finding root causes with 5 WHYS analysis. Results show dominant defects as spots (27%), black spots (19%), crooked runners (11%), folded bottoms (8%), flattened products (7%), and bubbles (7%), primarily due to unclean conditions and insufficient technician skills. Recommendations include providing supporting production tools, training workers, ensuring worker and tool cleanliness, and maintaining a clean preform warehouse to reduce defect rates in the Blow Molding process.