Quality Improvement Proposal of Spun Pile Using Six Sigma Method at PT. Adhi Persada Beton

Oct 26, 2026

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PT. Adhi Persada Beton produces precast concrete, including spun pile, but defect rates in spun pile production reached an average of 0.71% in 2020, exceeding the company standard of 0.5%. The study analyzes major defect types—fin, chipped, sticky skin, curved, and broken—and evaluates improvement priorities using DMAIC with DPMO (617) and sigma level (4.73). Apriori results show a strong combination between Curved and Sticky Skin, while FMEA prioritizes Fin. Proposed actions include rust removal, mold cleaning forms, and thermocouple-guided steaming control, though implementation is limited by a factory lockdown.

LanguageEnglish

CategoryResearch & Report

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Pages9

Reading Time23 min

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ABSTRACT

INTRODUCTION

DMAIC Stages and Methodology

Data and Quality Metrics

Advances in Engineering Research, volume 211 International Conference on Science and Engineering (ICSE-UIN-SUKA 2021) Quality Improvement Proposal of Spun Pile Using Six Sigma Method at PT. Adhi Persada Beton IntanArizka 1,* Dorina Hetharia 1 Anik Nur Habyba 1 1 Department of Industrial Engineering UniversitasTrisakti Jakarta, Indonesia *Corresponding author. Email: [intan063001700058@std.trisakti.ac.id](intan063001700058@std.trisakti.ac.id) ABSTRACT PT. Adhi Persada Beton is a subsidiary of PT. Adhi Karya (persero) tbk, which produces precast concrete, including spun pile. There was a problem in spun pile production; the average percentage of spun pile defects was 0.71%, exceeding the company standard, which was 0.5% . Therefore, this research was conducted to analyze the defect and provide improvement proposals to reduce the defective products. Five dominant defects that occurred were fin, chipped, sticky skin, curved, and broken. Based on the Spun Pile production process analysis, the DPMO of 617, and sigma level value of 4.73. Based on these criteria, the improvement proposal will be evaluated. The apriori algorithm indicated two defects have a strong combination relationship; they are Curved and Sticky Skin. Another defect prioritized to solve is Fin, the second-highest RPN from FMEA analysis. The use of rust remover can make the improvement proposal given to overcome fin defects. The use of mold cleaning forms is to overcome sticky skin and curved caused by unhardened concrete using a Thermocouple on steaming tubs. This research can only be carried out until the improvement stage because the proposed improvements cannot be implemented due to the lockdown situation at the factory. Keywords: DMAIC, apriori algorithm, FMEA, spun pile. 1. INTRODUCTION PT. Adhi Persada Beton is industry that produces precast concrete. Many products are produced, one of them is Spun Pile that had many defect issue. Spun Pile is a round hollow stake product produced by the centrifugal spinning method. It is usually used for bridges and buildings. Based on historical data in 2020, during the production of Spun Pile, several defective products occurred. Defects that occurred cause the product does not meet the quality standards that the company has set, so it requires quality improvement [1] . Based on historical data in Table 1, the average defect that occurred from January to December 2020 amounted to 0.71% exceeding the standard of PT. Adhi Persada Beton is 0.5% . The type of defect that occurs in Spun Pile products is sticky skin, chipped, porous, crack, fin, broken, dented joint plate, slanted joint plate, and curvy. Defective products cause loss of cost and time incurred by the company to repair or reproduce. DMAIC is a methodology of the six sigma approach that has been proven to improve product quality and reduce cost of poor quality (COPQ) [2] . The method used in this research is the DMAIC approach. Table 1.Historycal data of spun pile in Jan-Dec 2021 | No | Month | Total
Production | Defective
/Month
in pcs | Defective
Percentag
e | | --- | --- | --- | --- | --- | | 1 | January | 285 | 5 | 1.75% | | 2 | February | 161 | 1 | 0.62% | | 3 | March | 505 | 2 | 0.40% | | 4 | April | 371 | 2 | 0.54% | | 5 | May | 914 | 3 | 0.33% | | 6 | June | 1124 | 6 | 0.53% | | 7 | July | 1177 | 6 | 0.51% | | 8 | August | 1604 | 10 | 0.62% | | 9 | September | 274 | 5 | 1.82% | | 10 | October | 1510 | 6 | 0.40% | | 11 | November | 1197 | 7 | 0.58% | | 12 | December | 1684 | 7 | 0.42% | | AVERAGE | | 901 | 5 | 0.71% | Copyright © 2021 The Authors. Published by Atlantis Press International B.V. This is an open access article distributed under the CC BY-NC 4.0 license-[http://creativecommons.org/licenses/by-nc/4.0/.](http://creativecommons.org/licenses/by-nc/4.0/. 194)[ 194](http://creativecommons.org/licenses/by-nc/4.0/. 194) Advances in Engineering Research, volume 211 The stages of the DMAIC approach are D

FAQs

What defect problem prompted this Six Sigma research at PT. Adhi Persada Beton?

The average spun pile defect percentage was 0.71%, exceeding the company standard of 0.5%. The research focuses on analyzing defects and proposing improvements to reduce defective products.

Which defects were identified as the dominant issues in spun pile production?

Five dominant defects were identified: fin, chipped, sticky skin, curved, and broken. These defects formed the basis for the analysis and improvement proposals.

How were improvement priorities determined in the study?

DMAIC was used with DPMO (617) and sigma level (4.73) evaluation. Apriori identified Curved and Sticky Skin as strongly related, while FMEA prioritized solving Fin using the second-highest RPN.

Oct 26, 2026

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