Implementation Of the PDCA Method and Seven Tools to Minimize Rejects in the Blown Film Process at PT ABC

PT ABC experienced quality issues in the blown film process, characterized by high defect rates with defects such as uneven thickness, water spots, and color variations. These defects led to an increase in product returns by customers, waste of raw materials, and a decrease in production efficiency. This study aims to analyze the main causes of product defects and reduce the rejection rate in the molding process by applying the Plan-Do-Check-Act (PDCA) method and the Seven Quality Control Tools, which are expected to improve product quality at PT ABC. The research method used was quantitative descriptive with a case study approach conducted in the blown film production department of PT ABC. Data were collected through observation, interviews, and documentation of production reports. Analysis was performed using PDCA and seven tools, which included check sheets, Pareto charts, fishbone diagrams, histograms, and control charts to identify the main causes of defects. The results indicate that the dominant causes of defects were irregular filter replacement schedules and inadequate operator skills in die setting. Corrective actions were implemented through routine operator training and filter replacement in every shift. After implementation, The defect rate decreased from 2.10% to 0.97%, while customer returns declined from 21 cases in the second half of 2024 to 6 cases in the first half of 2025. This shows that the PDCA method and Seven Tools have proven effective in continuously improving production quality and efficiency at PT ABC.