Improving the quality of msme products using lean six sigma: A Case Study of Plastic Ball Production at UD. Billa Bola

Abstract

The implementation of Lean Six Sigma (LSS) has been widely adopted as an effective methodology to enhance quality and productivity in manufacturing and service sectors. By integrating Lean principles and Six Sigma tools, LSS provides a structured framework to minimize defects and eliminate non-value-added activities.This study applies the LSS methodology within a small-to-medium enterprise (SME), UD. Billa Bola, which manufactures plastic balls, aiming to improve production performance and reduce defect rates. Using the DMAIC (Define, Measure, Analyze, Improve, Control) approach, the research identifies dominant defects, analyzes process stability through control charts, measures sigma level improvements, and maps value stream efficiency. Results indicate a reduction in defect rate from 4.6% to 2.8%, an improvement of sigma level from 3.2 to 3.5, and a decrease in production lead time by 19%. These findings confirm that LSS not only enhances product quality but also increases operational efficiency in resource-constrained SMEs, highlighting its broader applicability beyond large-scale manufacturing