Continuously monitor and improve the production process

Oct 13, 2025 by recoveryshake.com 48 views

Improving the Sink Production Process with the Quality Function Deployment and Design for Manufacturing Approach at PT. Prima Indah Saniton

Introduction

In today's competitive market, companies are constantly seeking ways to improve their production processes and increase efficiency. One such company, PT. Prima Indah Saniton, has been facing a significant challenge in its sink production process. With a product disability level of 20.26% in each production period, the company recognized the need for comprehensive improvements. In this article, we will explore how the Quality Function Deployment (QFD) and Design for Manufacturing (DFM) methods were applied to improve the sink production process at PT. Prima Indah Saniton.

The QFD Approach in Identifying Production Needs

Quality Function Deployment (QFD) is a powerful tool used to explore the needs in the production process and connect them with the technical characteristics of the product. In QFD analysis, the entire production process is assessed based on the level of difficulty. The results of the processing show that most of the processes have a similar level of difficulty, except for mixing soil, pouring, plugging, and making printing, which are classified as easier.

The drying and burning process is a stage with the highest level of importance, with a value of 12. Identification of critical parts of the sink product is also carried out by referring to the literature and interviews with the production manager. It was found that the amount of clay and water are two important components that need to be fixed immediately. Both of these elements have a high level of difficulty and interest degree, each with a value of 5 and 4, as well as a significant cost estimate.

The QFD approach helps to identify the critical parts of the production process and prioritize improvements. By understanding the level of difficulty and importance of each process, the company can focus on the areas that need the most attention. In this case, the QFD analysis revealed that the drying and burning process is a critical stage that requires improvement.

Implementation of the Design for Manufacturing (DFM) Method

After identifying the part that needs to be improved, the next step is to apply Design for Manufacturing (DFM). DFM is used to increase product design and minimize time, energy, and production costs. One of the improvements made is the combination of the elements of the demolition of the printed outcome by cooling the printout. With changes in the composition of raw materials, the length of drying activities can be reduced, so that the efficiency of the production process increases.

Other innovations involve the addition of floculants as a substitute for water to increase soil plasticity and speed up the drying process. In this case, biosludge from 1 kg of paper pulp waste is added to every 8 kg of material in one sink unit. With the application of this substance, the elements of drying activities can be minimized, impact on reduction of time and operating costs.

The implementation of DFM has resulted in significant improvements in the production process. By reducing the length of drying activities and minimizing the use of water, the company has been able to increase efficiency and reduce costs.

Results and Impact of Improvement

The ratio between conditions before and after repairs shows a significant difference in operating time. Theoretically, reducing the work elements has occurred, so that the production time is reduced. In addition, there is a reduction in production costs which include direct material costs and labor costs. In other words, the application of QFD and DFM at PT Prima Indah Saniton not only improves product quality, but also increases the efficiency of the process and reduces operational costs.

The results of the improvement are significant, with a reduction in product disability level from 20.26% to a negligible level. This is a testament to the effectiveness of the QFD and DFM methods in improving the production process.

Conclusion

The application of the Quality Function Deployment and Design for Manufacturing method has proven to be effective in improving the sink production process at PT Prima Indah Saniton. With a focus on customer needs and optimizing the production process, companies are not only able to reduce the level of product disability, but also increase efficiency and reduce costs. This innovation is an important step for companies in maintaining competitiveness in the sanitation industry.

In conclusion, the QFD and DFM methods have been successfully applied to improve the sink production process at PT Prima Indah Saniton. The results of the improvement are significant, with a reduction in product disability level and an increase in efficiency and reduced costs. This case study demonstrates the effectiveness of the QFD and DFM methods in improving production processes and increasing competitiveness in the market.

Recommendations

Based on the results of this case study, the following recommendations are made:

Continuously monitor and improve the production process: The QFD and DFM methods should be continuously applied to monitor and improve the production process.
Invest in training and development: The company should invest in training and development programs to ensure that employees have the necessary skills and knowledge to implement the QFD and DFM methods.
Encourage a culture of innovation: The company should encourage a culture of innovation and continuous improvement, where employees are encouraged to suggest new ideas and improvements.
Monitor and evaluate the impact of improvements: The company should regularly monitor and evaluate the impact of improvements on the production process and customer satisfaction.

By following these recommendations, companies can ensure that they remain competitive in the market and continue to improve their production processes.

Limitations of the Study

This case study has several limitations, including:

Limited scope: The study only focused on the sink production process at PT Prima Indah Saniton and did not consider other production processes.
Limited data: The study relied on secondary data and did not collect primary data from the company.
Limited time frame: The study only considered a limited time frame and did not consider the long-term impact of the improvements.

Despite these limitations, the study provides valuable insights into the application of the QFD and DFM methods in improving the production process.

Future Research Directions

Future research should focus on:

Applying the QFD and DFM methods in other production processes: The study should be replicated in other production processes to determine the effectiveness of the QFD and DFM methods.
Investigating the impact of the QFD and DFM methods on customer satisfaction: The study should investigate the impact of the QFD and DFM methods on customer satisfaction and loyalty.
Developing a framework for implementing the QFD and DFM methods: The study should develop a framework for implementing the QFD and DFM methods in production processes.

By following these research directions, companies can continue to improve their production processes and increase competitiveness in the market.
Q&A: Improving the Sink Production Process with the Quality Function Deployment and Design for Manufacturing Approach

In our previous article, we explored how the Quality Function Deployment (QFD) and Design for Manufacturing (DFM) methods were applied to improve the sink production process at PT. Prima Indah Saniton. In this article, we will answer some of the most frequently asked questions about the QFD and DFM methods and their application in the sink production process.

Q: What is Quality Function Deployment (QFD)?

A: Quality Function Deployment (QFD) is a powerful tool used to explore the needs in the production process and connect them with the technical characteristics of the product. It is a method that helps to identify the critical parts of the production process and prioritize improvements.

Q: What is Design for Manufacturing (DFM)?

A: Design for Manufacturing (DFM) is a method used to increase product design and minimize time, energy, and production costs. It involves designing products and processes to be easy to manufacture, reducing the need for rework and improving overall efficiency.

Q: How did the QFD and DFM methods improve the sink production process at PT. Prima Indah Saniton?

A: The QFD and DFM methods helped to identify the critical parts of the production process and prioritize improvements. By reducing the length of drying activities and minimizing the use of water, the company was able to increase efficiency and reduce costs.

Q: What were the results of the improvement?

A: The results of the improvement were significant, with a reduction in product disability level from 20.26% to a negligible level. This is a testament to the effectiveness of the QFD and DFM methods in improving the production process.

Q: How can companies apply the QFD and DFM methods in their own production processes?

A: Companies can apply the QFD and DFM methods by following these steps:

Identify the critical parts of the production process: Use QFD to identify the critical parts of the production process and prioritize improvements.
Design for manufacturing: Use DFM to design products and processes to be easy to manufacture, reducing the need for rework and improving overall efficiency.
Monitor and evaluate the impact of improvements: Regularly monitor and evaluate the impact of improvements on the production process and customer satisfaction.

Q: What are the benefits of applying the QFD and DFM methods?

A: The benefits of applying the QFD and DFM methods include:

Improved efficiency: By reducing the length of drying activities and minimizing the use of water, companies can increase efficiency and reduce costs.
Reduced product disability level: By identifying and prioritizing improvements, companies can reduce the product disability level and improve overall quality.
Increased customer satisfaction: By improving the production process and reducing product disability level, companies can increase customer satisfaction and loyalty.

Q: What are the limitations of the QFD and DFM methods?

A: The limitations of the QFD and DFM methods include:

Limited scope: The QFD and DFM methods may not be applicable to all production processes.
Limited data: The QFD and DFM methods rely on secondary data and may not provide a complete picture of the production process.
Limited time frame: The QFD and DFM methods may not consider the long-term impact of improvements.

Q: What are the future research directions for the QFD and DFM methods?

A: Future research should focus on:

Applying the QFD and DFM methods in other production processes: The study should be replicated in other production processes to determine the effectiveness of the QFD and DFM methods.
Investigating the impact of the QFD and DFM methods on customer satisfaction: The study should investigate the impact of the QFD and DFM methods on customer satisfaction and loyalty.
Developing a framework for implementing the QFD and DFM methods: The study should develop a framework for implementing the QFD and DFM methods in production processes.

By following these research directions, companies can continue to improve their production processes and increase competitiveness in the market.

Conclusion

The QFD and DFM methods have proven to be effective in improving the sink production process at PT. Prima Indah Saniton. By identifying the critical parts of the production process and prioritizing improvements, companies can increase efficiency and reduce costs. We hope that this Q&A article has provided valuable insights into the application of the QFD and DFM methods and has helped to answer some of the most frequently asked questions about these methods.