Defective Reduction in Carton Box Manufacturing Using Design of Experiment (DOE)

Abstract

This research aimed to reduce the defective form carton box process using industry engineering technique for categorizing the potential causes of a problem to obtain defective in the carton box process. Response Surface Experiment was used to design the experiment by three factors consisting of 1) Speed machine at 170-190 m/min, 2) Glue gap at 370-400 micron, and 3) Glue Machine at 380-390 microns with significance at 0.05. The summarized results were suitable parameters for setting up the machine in producing carton box where the speed at 190 meters/ minute, the glue gap at 390 microns, and the glue Machine at 385 effects to highly compressive force at 103.27 kg. f/cm² and reduce defective brittle paper. The before improvement result shows a defective ratio average of 5.86%, and after improvement using Response Surface Experiment (Box-Behnken) result shows a defective ratio average of 1.83 %. So, the summarized results were as follows before improving the total monthly defective ratio average of 7.33%. The brittle paper was mostly defective to reduce after improvement. The total defective (Monthly) ratio was also reduced by 3.28%, and the manufacturer can do meet the target that the Total monthly defective ratio average of less than 4.5%.