Improving the Quality of the Plastic Woven Basket Production Process Using the Plan-Do-Check-Action (PDCA) Cycle (Case Study: CV Karya Abadi)
Keywords:
PDCA, quality improvement, defect reduction, plastic weaving, process standardizationAbstract
This study evaluated quality improvement in the production of plastic-woven bojok at CV Karya Abadi using the Plan–Do–Check–Action (PDCA) cycle. Initial observations over ten production days recorded 150 units and 104 defect occurrences, consisting of 84 cases of insufficiently dense weaving, 10 loose-weaving defects, and 10 series-weaving defects. The dominant defect represented 80.77% of total occurrences. Root-cause analysis identified contributing factors related to man, method, material, machine, and environment. Corrective measures were then implemented through standardized work instructions, in-process checkpoints, raw-material inspection, plastic-rope sorting, a new tightening tool, and work-position adjustment. After implementation during 10–19 August 2026, total defect occurrences decreased to 38, comprising 27 insufficiently dense weaving defects, seven loose-weaving defects, and four series-weaving defects. Using the same production comparison basis of 150 units, the reported defect percentage fell from 69.33% to 25.33%, while total defects declined by 63.46%. The findings indicate that PDCA provided a structured basis for identifying defects, implementing corrective measures, evaluating outcomes, and establishing improved practices as production standards. These results demonstrate measurable improvement in process consistency and support periodic evaluation of standardized corrective practices.
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