Quality Control of Corrugated Carton Boxes Using Statistical Process Control to Minimize Defects at PT Bahana Buana Box
Keywords:
Control Chart, Corrugated Sheet, Defect Analysis, Quality Control, Statistical Process Control.Abstract
Corrugated carton manufacturing requires consistent sheet alignment, bonding, and dimensional conformity, yet defects in the corrugating process can increase material waste. This study assessed defect frequency, production stability, and potential corrective priorities at PT Bahana Buana Box. A descriptive quantitative observational design examined production and quality-assurance records from 30 production observations collected on 2–5 June 2026. Check sheets, a histogram, Pareto analysis, a p-control chart, and cause-and-effect diagrams were used. Among 57,760 corrugated sheets produced, 835 were rejected, representing a rejection rate of 1.45%. Misalignment was the largest category (388 sheets; 46.47%), followed by surface cracking (135), splice marks (127), delamination (105), and sheet buckling (80). The three leading categories accounted for 77.84% of recorded rejects. Under the originally reported constant control limits, 15 observations fell outside the specified boundaries, including 11 above the upper limit and four below the lower limit. Because production-run sizes differed, these classifications require independent verification using observation-specific limits. Potential contributing factors involved personnel, machinery, materials, operating methods, and environmental conditions. Recommended actions included operator inspection, preventive maintenance, material verification, standardized machine settings, and adhesive and environmental monitoring. The proposed measures were not implemented or evaluated; subsequent production monitoring is required to assess their effectiveness.
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