176 © 2017 AESS Publications. All Rights Reserved. APPLICATION OF LEAN SIX SIGMA AND THEORY OF INVENTIVE PROBLEM SOLVING TO REDUCE WASTE AND IMPROVE THE QUALITY MOTORCYCLE REAR ARM Rahmat Nurcahyo 1+ Riadhi Apdillah 2 Yadrifil 3 1,2,3 Departemen Teknik Industri, Universitas Indonesia (+ Corresponding author) ABSTRACT Article History Received: 28 April 2017 Revised: 23 May 2017 Accepted: 29 May 2017 Published: 2 June 2017 Keywords Lean six sigma TRIZ VSM Waste Defects Cycle time Takt time Efficiency In a competitive global market, the need of high quality product and high efficiency production are increasing. An automotive spare part company is facing this problem because the production is not efficient and the defect ratio is still above the target. The company develops and makes an aluminum rear frame arm for motorcycle spare part. The purpose of this study is to improve production quality and efficiency by applying lean six sigma. The lean six sigma objectives are to reduce waste, non-value added work and cycle time. Based on the initial analysis, the sigma level of the company was at 3.8 sigma. The waste from the production process was 26.29%, unnecessary inventory was 20, 45%, and over production was 16.85%. The lean six sigma methodology of DMAIC (define, measure, analyze, improve, and control) is used for this study. The value stream mapping (VSM) is used to identify the waste while theory of inventive problem solving (known as TRIZ) is used at analysis and improvement stage to overcome the production defect problems in the production line. The result of this study shows that the sigma level is increased to 4,8 sigma with defect ratio of 0,51%. Contribution/ Originality: This study contributes in the existing literature of lean six sigma implementation.. This study integrated lean six sigma with value strem mapping (VSM) and theory of inventive problem solving (known as TRIZ) to improve lean six sigma implementation. 1. INTRODUCTION Lean is a process to increase efficiency. The concept was first proposed by Taiichi Ohno and Shigeo Shingo at Toyota production system, also became known as lean manufacturing. Lean manufacturing requires not only technical understanding of the complete manufacturing system, but also to understand the relationship that exists between manufacturing and other areas of the company such as supply chain management, customer demand and perceptions, distribution and logistics [1]. Six Sigma is a business improvement strategy that seeks to identify and remove the causes of defects or errors in business processes by concentrating on activities that are relevant to the Journal of Asian Scientific Research ISSN(e): 2223-1331 ISSN(p): 2226-5724 DOI: 10.18488/journal.2.2017.75.176.186 Vol. 7, No. 5, 176-186 © 2017 AESS Publications. All Rights Reserved. URL: www.aessweb.com