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PT Kusuma Mulia Plasindo Infitex is a company engaged in the manufacturing sector that produces polypropylene and HD (Hight density Polyethylene) plastic products. The problem that occurred at PT Kusuma Mulia Plasindo Infitex was that the number of defective products on HD plastic products of 98,327 kg contained 4,194 kg of defective products. The purpose of this study is to determine the factors that cause defects and suggestions for improvements to minimize defective products. This study uses the six sigma method which is useful for finding the root causes of problems that are adjusted to the characteristics of the data they have. The 5 stages of six sigma are DMAIC(define, measure, analyze, improve, control) and kaizen is the Five M-Checklist. So from the results of data processing, the value is obtained in the form of DPMO 8393.048 and a sigma value of 2.49. Proposed improvements include providing training in plastic welding, providing additional 5-10 minute breaks and supervision while working. Perform routine machine maintenance every month and cleaning every day. Adding ventilation and blowers in the production room. Carry out the production process according to the existing SOP at the company, especially in mixing materials according to the SOP for raw materials that have been made by the company.

In an effort to increase productivity to ensure smooth production processes, it is necessary to implement an appropriate maintenance system to reduce production machine downtime. The purpose of company maintenance is to keep production machines in good condition so that production operations can run efficiently and effectively. PT Yale Woodpallet Indonesia is a company in Indonesia that produces wooden pallets (wood pallet). This company often experiences problems with damage to machines due to suboptimal machine maintenance because the maintenance system is carried out to repair damaged components with new components resulting in downtime. Among these problems, this study aims to determine maintenance intervals to minimize maintenance costs by using modularity design and age replacement methods. Based on the analysis of the results obtained, it is known that the modularity design and age replacement methods can achieve optimal component replacement intervals for pallet machine components is 30,000 minutes, rotary screening components are 33,200 minutes and hopper components are 33,200 minutes. The total maintenance cost per year is Rp. 2,115,610,959, -. compared to the company's maintenance costs which have a value of Rp. 2,668,692,000, the maintenance system using the modularity design and age replacement method is more efficient by 1.27%.

Developments in the industrial world are increasingly rapid, resulting in increased competition in the industrial world, so that industrial companies are competing to improve production efficiency and effectiveness. Especially companies in the manufacturing sector, increasing productivity in a production system is an absolute thing that must be done. One of the main indicators in increasing productivity is the level of rehabilitation of production machines at the company. In measuring how good the rehabilitation of a production machine is, an effective and efficient maintenance maintenance process is needed for the company. Continuous use of the machine will decrease the level of readiness of the machine itself. In an effort to maintain the level of machine readiness so that production results are guaranteed due to continuous use of the machine, regular machine maintenance and maintenance activities are needed which are expected to prolong the condition of production machines so that they are not damaged, in case of machine damage it can disrupt production activities.