Improving the quality of the chocolate production process at Wahana Interfood Nusantara company using DMAIC method

Abstract

A company that prioritises quality will have an advantage in the global market because not all companies can achieve and sustain high levels of quality. Wahana Interfood Nusantara Company is Indonesia's most complete cocoa bean processing company under the SCHOKO brand. The company processes raw cocoa beans to produce high-quality chocolate and cocoa products. One of the products that experienced defects at Wahana Interfood Nusantara Company was the white couverture chocolate product. The problem statement of this study was what types of defects contribute to the poor quality of white couverture chocolate and what factors contribute to the defects. The aim and objectives of this study were to identify and analyse the current quality state of the production process of Product White Couverture chocolate at Wahana Interfood Nusantara company, Analyse the data collected during the production process of Product White Couverture chocolate to come up with root causes and identify the optimum solution, and Identify improvements made because of proposed solutions. This study uses the DMAIC method (Define, Measure, Analyze, Improve, and Control). They obtained 5 Critical to Quality chocolate attributes: broken, cracked, peeled-off, soft, and porous. Regarding the p-chart control calculation, the CL, UCL, and LCL values were 0.024, 0.026, and 0.022. It means the data result is in control. The DPMO value was 4788.49, and the Sigma value was 2.496, which means that the white couverture chocolate production process is in Indonesia's average Sigma value industry. It was found that 80% of the most dominant defects were peeled off (38.5%), cracked (28.7%), and broken (25.3%). The identified factors include workers or employees (people), tools (equipment), the environment (environment), and methods (methods). Suggestions for improvements are given to maintain regular machine maintenance, conduct employee training, and carry out SOPs correctly.