Kaizen implementation to reduce dimensional defect in the welding process of Fender D155A-6R at PT Arkha Jayanti Persada

I.G.B.E.P. Yana, P.D. Setyawan, I.M. Suartika, A. Rachmalia, M.M. Aziz

Abstract


Kaizen is a concept of continuous improvement that emphasizes quality enhancement and efficiency in production processes. In this study, the Kaizen approach was applied to address dimensional defects in the welding process of the Fender D155A-6R component at PT. Arkha Jayanti Persada. The component, which was previously imported from Japan, is currently being tested through local production trials. Initial inspection indicated that 11 of 33 measurement points were out of tolerance, most of which were linked to welding activities. To analyze the problem, the PDCA (Plan, Do, Check, Act) cycle was employed. The investigation revealed several contributing factors: the absence of a locator to secure parts during welding, insufficient reinforcement that caused deformation, and the lack of a standardized welding procedure for operators. Corrective measures were then introduced, including the installation of a locator, additional reinforcements, and the establishment of a formal welding procedure. After two PDCA cycles, the dimensional issues were successfully resolved. The findings indicate that applying Kaizen through PDCA led to significant improvements in dimensional accuracy and product quality.

Keywords


Kaizen implementation; Plan do check action; Improvement; Dimensional defect; Welding process

Full Text:

PDF

References


Adawia, P.R., Azizah, A., Analisis penerapan metode Kaizen terhadap importasi material produksi pada perusahaan manufaktur. Target: Jurnal Manajemen Bisnis, 2(1), 56-70, 2020.

Andita, S.A., Rahayu, S., Windyatri, H., Penerapan DMAIC Six Sigma dan FMEA untuk meningkatkan kualitas produk di pt Xyz menuju zero defect. Jurnal KaLIBRASI: Karya Lintas Ilmu Bidang Rekayasa Arsitektur, Sipil, Industri, 8(2), 58-69, 2025.

Ariani, B., Ponidi., Akmal, H., Deformation analysis of the stringer welding process on the support frame vibrating screen. Rekayasa Sistem Energi dan Manufaktur (ReSEM), 2(1), 52-60, 2024.

Basuki., Upaya peningkatan kualitas dengan menggunakan analisis siklus PDCA pada perusahaan otomotif. Jurnal Metris, 24(1), 9–16, 2023.

Fatah, A., Al-Faritsy, A.Z., Peningkatan dan pengendalian kualitas produk dengan menggunakan metode PDCA (studi kasus pada PT. X). Jurnal Rekayasa Industri (JRI), 3(1), 21-30, 2021.

Guo, N., Hu, H., Tang, X., Ma, X., Wang, X., The effect of TIG welding heat input on the deformation of a thin bending plate and its weld zone. Coatings, 13(12), 2008, 2023.

Jannah, S.A., Hayuningtias, K.A., Pengaruh kualitas produk dan persepsi harga terhadap kepuasan pelanggan serta dampaknya pada loyalitas pelanggan. Jesya (Jurnal Ekonomi dan Ekonomi Syariah), 7(1), 489-500, 2024.

Juhaeti., Pengaruh penerapan standar operasional prosedur dan quality control terhadap kualitas produk PT. IK Precision Indonesia Cikarang Jawa Barat. Jurnal Ilmiah M-Progress, 14(1), 84-97, 2024.

Nguyen, V., Nguyen, N., Schumacher, B., Tran, T., Practical application of plan–do–check–act cycle for quality improvement of sustainable packaging: a case study. Applied Sciences, 10(18), 6332, 2020.

Nugrowibowo, S., Rosyidi, M.R., Pengendalian kualitas produk aluminium alloy wheel dengan metode Seven Tools dan PDCA. Jurnal Informasi, Sains dan Teknologi, 6(1), 104-119, 2023.

Pangestu, W.F., Suhendra., Khofiyah, N.A., Analisis penurunan defect pada komponen print circuit board (pcb) menggunakan metode PDCA dan aplikasi kaizen di PT Dei. Journal Industrial Engineering and Management (JUST-ME), 6(01), 10-18, 2025.

Pranata, D., Windyatri, H., Suhendra., Analisis pengendalian kualitas produk barrel menggunakan metode Kaizen dan PDCA framework di PT. Xyz. JUTIN: Jurnal Teknik Industri Terintegrasi, 7(4), 2422–2432, 2024.

Rajić, M.N., Stanković, Z.Z., Mančić, M.V., Milosavljević, P.M., Maksimović, R., Business process reengineering with a circular economy PDCA model from the perspective of manufacturing industry. Processes, 12(5), 877, 2024.

Rangel-Sánchez, M.Á., Urbina-González, J.D.J., Carrera-Escobedo, J.L., Guirette-Barbosa, O.A., Murillo-Rodríguez, V.A., Celaya-Padilla, J.M., Durán-Muñoz, H.A., Cruz-Domínguez, O., Enhancing scrap reduction in electric motor manufacturing for the automotive industry: A case study using the PDCA (Plan–Do–Check–Act) approach. Applied Sciences, 14(7), 2999, 2024.

Samadi, H., Ahsan, M.M., Raman, S., Metrology and manufacturing-integrated digital twin (MM-DT) for advanced manufacturing: Insights from coordinate measuring machine (CMM) and faro arm measurements. Next Research, 2(2), 100299, 2025.

Singh, J., Gandhi, S.K., Benefits using PDCA cycle of continuous improvement in manufacturing industry-a case study. International Journal of Management Concepts and Philosophy, 17(1), 83-97, 2023.

Sumasto, F., Maharani, C.P., Purwojatmiko, B.H., Imansuri, F., Aisyah, S., PDCA method implementation to reduce the potential product defects in the automotive components industry. IJIEM-Indonesian Journal of Industrial Engineering and Management, 4(2), 87, 2023.

Widianto, A.R., Rahmawati, P., Khofiyah, N.A., Analisis pengendalian kualitas produk assy water menggunakan metode pdca di perusahaan otomotif. Jurnal Teknologi dan Manajemen Industri Terapan, 4(3), 896-907, 2025.




DOI: https://doi.org/10.29303/dtm.v15i2.1158

Refbacks

  • There are currently no refbacks.


Copyright (c) 2025 Open access

Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

After being re-accredited, the Journal of Dinamika Teknik Mesin, still has sinta 3 (S3) which is valid until 2025.