PRODUCT DEFECTS ANALYSIS AT PT NAIGAI SHIRTS INDONESIA USING PROCESS CONTROL STATISTICS AND PROCESS CAPABILITY ANALYSIS
DOI:
https://doi.org/10.35261/barometer.v11i2.13217Abstract
The garment industry is a labor-intensive sector that plays a significant role in Indonesia’s economic development, however quality-related problems often limit it’s competitiveness. PT Naigai Shirts Indonesia, located in Karawang, experienced a relatively high defect rate in the sewing process, reaching more than 1,300 defective units with 2,21% of total monthly production in December 2024. This study aims to identify the dominant causes of product defects and evaluate the capability of the production process using Statistical Process Control (SPC) and Process Capability Analysis (PCA). The research employed field observations, literature review, and secondary data obtained from Quality Control production and defect reports. Data analysis was conducted using histograms and Pareto charts to identify dominant defect types, P-control charts to evaluate process stability, and using Cp and Cpk calculations to assess process capability. The results indicate that the Kumitate II department was the largest contributor to defects, with 516 defective units. The most dominant defect type was susomaki with 258 units. Initial P-control chart analysis revealed that the process was statistically unstable; however, after corrective actions were implemented, the process returned within control limits. Process capability analysis produced a Cp value of 0.73 and a Cpk value of 0.67, indicating that the process is not capable and does not meet specification requirements. An Ishikawa analysis classified the root causes of defects into five factors: man, machine, method, material, and measurement. maintenance, and quality standardization to reduce defect rates and improve process capability.
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