Process Capability Analysis and Its Refinement in Producing the Standard White Sugar Using DMAIC Approach

The white crystal sugar is a principal ingredient to make the various beverages and foods. It is also employed as seasoning in (daily) cooking. In order that getting high quality of output produced, the sugar should be manufactured fit a standard. However, many factories still fail to produce the standard white sugar in which some defects were resulted from process such as sugar color defects, gravel sugar defects, ash sugar defects, and scrap sugar defects. This matter may be able to cause a low quality of output produced. Thus, it is crucial to refine the process capability of the sugar production. Objective of the study is to evaluate the existing process and improve it to prevent the defects during the process of sugar. The six-sigma method and Fishbone Diagram is implemented to analyze the existing process capability and 5W+1H (what, where, when, who, why and how) method is used to develop some recommendation from improvement. All these stages are in accordance with the DMAIC concept. Result of this study show that the existing process capability is found as much as 4.13 sigma which it has not been able to produce standard of six sigma. Therefor some recommendation for improvement should be done. They supervise and provide warnings to operators to be more focused on doing work, make a routine machine maintenance schedule and check the machine before use so that the production machines are really ready for use, ensure raw materials meet MBS standards (sweet, clean, fresh) by increasing supervision of sugarcane quality inspection on the scales and carry out the process of drying raw materials, and add air vents and exhaust fans to reduce heat, provide ear plugs for operators to reduce noise, and routinely clean the environment to remove standing water.