Achieving Zero-Defect Production: A Data-Driven Strategy for Reject Reduction in a B2B Frozen Food Factory

Pandu Wijaya; Agustinus Hariadi Djoko Purwanto

doi:10.55927/ajabm.v4i3.441

Authors

Pandu Wijaya Mercu Buana University
Agustinus Hariadi Djoko Purwanto Mercu Buana University

DOI:

https://doi.org/10.55927/ajabm.v4i3.441

Keywords:

Lean Six Sigma, Operational Sustainability, Reject Reduction, Quality Management, Food Industry

Abstract

This study aims to formulate a data-driven strategy to reduce high product reject rates at a B2B frozen food factory. High rejects threaten productivity and operational sustainability. This research employs an explanatory sequential mixed-methods design. The quantitative phase analyzes production and reject data from 2023-2025 using Pareto Analysis and Statistical Process Control (SPC) with a census sample. The qualitative phase uses interviews and a Focus Group Discussion (FGD) to explore root causes. Results show the process is statistically out of control, with 80.5% of rejects from 40 products. Key root causes are reactive maintenance, process bottlenecks, and a lack of formal operator competency standards.

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