Strength improvement of fibre cement product

This paper presents a methodology to improve the strength or the Modulus of Rupture (MOR) of fibre cement. The Six Sigma approach with the DMAIC steps was applied to a case study company. This research started from defining problem, setting the project objective and the project scope. Next, the measurement system was analyzed and the process map was set up. The potential factors of the problem was then determined. Due to there were many factors that affect the MOR, the Cause and Effect Matrix and the Failure Mode and Effect Analysis technique were then used to reduce the number of factors to be studied further. Next, three process factors, which were the pulp slurry freeness, the film-layer thickness, and the pressure step, were optimized using the results from the Box-Behnken experimental design. Other 13 remaining factors were improved by creating or revising the standard work instructions and training the operators. After that, the statistical process control and the control plan were set up to control the production processes. After improvement, the process capability index (Ppk) significantly increased from 0.26 to 1.35.