Lean Six Sigma Approach to Reduce Miss Shooting Bag Waste in Cement Packaging

Background: Competition in the cement industry in Indonesia encourages companies to maintain production quality and efficiency. One cement company in Tuban Regency frequently faces the problem of miss-shooting bag in the cement packaging process, namely the failure of the rotary packer machine to shoot cement bags onto the filling spout, causing the bags to fall and resulting in waste. Objective: This study aims to identify the types of waste that occur, analyze the factors causing miss-shooting bag, and formulate improvement recommendations using the Lean Six Sigma approach. Methods: This study uses a quantitative descriptive research design with the DMAIC approach (Define, Measure, Analyze, Improve, Control), focusing on the Define, Measure, Analyze, and Improve stages. Data were collected through direct observation, interviews with packer operators, and secondary production records from June 2024 to May 2025 at PT X in Tuban, East Java. Results: The results show that miss-shooting bag causes defect waste and overprocessing waste. The sigma values for defects on packer machines 1 and 2 are 4.63 and 4.62, respectively, indicating that process quality is already good but still requires improvement. The fishbone diagram analysis identifies factors causing miss-shooting bag, including human, machine, material, method, and environmental factors. Conclusion: The proposed improvement recommendations include establishing bag quality standards, conducting routine machine maintenance, improving workplace cleanliness, and providing a dedicated rest area for workers to reduce miss-shooting bag incidents and improve the efficiency of the cement packaging process.