International Research Journal of Innovations in Engineering and Technology - IRJIET International Open Access, Monthly, Peer Reviewed, Reputed Journal ISSN (online): 2581-3048

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DOI Prefix: 10.47001/IRJIET

Case Study on the Application of Six Sigma DMAIC for Reducing Product Rejects in VRLA Battery Production

Norman IskandarMechanical Engineering, Diponegoro University, Semarang, IndonesiaAfif Nashafa Al QaumaMechanical Engineering, Diponegoro University, Semarang, IndonesiaSulardjakaMechanical Engineering, Diponegoro University, Semarang, Indonesia

Vol 9 No 5 (2025): Volume 9, Issue 5, May 2025 | Pages: 246-253

International Research Journal of Innovations in Engineering and Technology

OPEN ACCESS | Research Article | Published Date: 24-05-2025

doi Logo doi.org/10.47001/IRJIET/2025.905033

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Abstract

The high reject rate in the VRLA battery production process has become a critical issue affecting both efficiency and product quality. This study aims to reduce the reject rate by applying the Six Sigma methodology through the DMAIC approach (Define, Measure, Analyze, Improve, Control). The tools utilized include the Pareto diagram, DPMO and Sigma Level trend charts, and the 5 Why Analysis to identify root causes. The implementation results demonstrate a reduction in product mismatch rate from 4.2% to 1.1%. The average weekly DPMO decreased from 23,544.74 to less than 5,000, while the Sigma Level improved from 3.5 to above 4.0. The application of the Six Sigma methodology proved effective in enhancing process capability and reducing product defects.

Keywords

Six Sigma, DMAIC, VRLA battery, DPMO, defect reduction


Citation of this Article

Norman Iskandar, Afif Nashafa Al Qauma, & Sulardjaka. (2025). Case Study on the Application of Six Sigma DMAIC for Reducing Product Rejects in VRLA Battery Production. International Research Journal of Innovations in Engineering and Technology - IRJIET, 9(5), 246-253. Article DOI https://doi.org/10.47001/IRJIET/2025.905033

Licence Copyright (c) 2026 International Research Journal of Innovations in Engineering and Technology creative common licence This work is licensed under Creative common Attribution Non Commercial 4.0 Internation Licence
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