การประยุกต์ใช้เทคนิคซิกซ์ ซิกม่าเพื่อลดร้อยละผลิตภัณฑ์ที่มีข้อบกพร่องในกระบวนการผลิตไส้กรอกไก่รมควันแฟรงค์เฟอร์เตอร์

Abstract

The processing of smoked chicken frankfurter of the case study factory set the percentage of acceptable non-conforming products not more than 3.00. In present, this criterion was 3.44 which was higher than the target resulting in high production cost. This research aimed to reduce the non-conforming products more than 50 percentage. The study conducted by applying six sigma technique including 5 phases that were define, measure, analyse, improvement and control. From the survey of current situation, it was found that over length sausages was the highest type of non-conforming products. The analysis on processing steps of smoked chicken frankfurter shown that only 5 steps from 17 main steps that affected to root cause of non-conforming products. Then main input factors of each step were identified by using the process mapping. The results shown that there were 41 of key process input variable (KPIV) on 5 steps. After that Failure Mode and Effects Analysis with calculating risk priority number (RPN) was used for selecting the important factors. By ranking scores with pareto diagram, only 18 KPIVs were compliance with causes of non-conforming products. After discussed with management team of case study factory in term of operation, technical feasibility, production planning, the impact to the production. Three KPIVs were selected which were 1) quality of casing 2) showering sausages before peeling and 3) setting of propellers of arranging sausages machine. Then hypothesis testing was processed with statistical program. It was found that 3 KPIVs significantly affected to non-conforming products at significant level 0.05. The improvement methods were changing the new casing from type A to type B in stuffing step, setting 40 second with 6 sausages sticks to shower sausages before peeling, and setting propeller at level 3 for arranging sausages machine in packing sausages step. In control phase, the control program was made and established to control all factors which were improved. After implementation, the percentage of non-conforming products reduced from 3.44% to 1.70% which was about 50.6%. The cost of the factory case study decreased 3,365,421.7 Baht per year.