Quality Control Analysis Using the PDCA (Plan, Do, Check, Action) Method to Reduce Carton Packaging Returns at PT. App Purinusa Ekapersada Demak

Intany Salsabiela; Riandhita Eri Werdani

doi:10.14710/jvsar.27694

DOI: https://doi.org/10.14710/jvsar.27694

Quality Control Analysis Using the PDCA (Plan, Do, Check, Action) Method to Reduce Carton Packaging Returns at PT. App Purinusa Ekapersada Demak

Intany Salsabiela, Riandhita Eri Werdani

Department of Business and Finance, Vocational College, Universitas Diponegoro, Indonesia

Received: 10 Jun 2025; Revised: 20 Jan 2026; Accepted: 9 Apr 2026; Available online: 28 Apr 2026; Published: 30 Apr 2026.

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.

BibTex Citation Data :

@article{JVSAR27694,
    author = {Intany Salsabiela and Riandhita Eri Werdani},
    title = {Quality Control Analysis Using the PDCA (Plan, Do, Check, Action) Method to Reduce Carton Packaging Returns at PT. App Purinusa Ekapersada Demak},
    journal = {Journal of Vocational Studies on Applied Research},
  volume = {8},
    number = {1},
    year = {2026},
    keywords = {PDCA; Quality Control; Carton Packaging Returns; Continuous Improvement; Carton Packaging Industry},
    abstract = { PT APP Purinusa Ekapersada Demak is a packaging company that produces carton sheets and carton boxes for various industries, with more than 100 customers in 2024. However, the company is facing an increase in the number of products returns due to damage that occurs during the distribution process, product non-conformity to the specified specifications, and product handling procedures that are still not running optimally. Analysis of production data and the 2022-2024 return period shows that the total return of carton sheets and carton boxes exceeds the maximum limit set, with the main damage being rust. This study aims to control quality by implementing the PDCA (Plan, Do, Check, Action) method to reduce the return rate and increase production efficiency. The research method uses a qualitative descriptive approach with observation, interview, and documentation techniques. The analysis was carried out through a Pareto diagram to determine problem priorities, a cause-and-effect diagram (fishbone) to identify the main causes, and 5W + 1H and control charts for process evaluation and monitoring. The implementation results showed a significant decrease in the level of damage, especially for rust defects, after improvements were made to human, material, machine, method, and environmental factors. Key recommendations include operator training, evaluation of supplier governance assessments, routine machine maintenance, and updating of standard operating procedures (SOPs) to ensure continuous improvement and increase customer satisfaction. },
   issn = {2684-8090},   pages = {22--31}  doi = {10.14710/jvsar.27694},
    url = {https://ejournal2.undip.ac.id/index.php/jvsar/article/view/27694}
}

Citation Format:

Abstract

PT APP Purinusa Ekapersada Demak is a packaging company that produces carton sheets and carton boxes for various industries, with more than 100 customers in 2024. However, the company is facing an increase in the number of products returns due to damage that occurs during the distribution process, product non-conformity to the specified specifications, and product handling procedures that are still not running optimally. Analysis of production data and the 2022-2024 return period shows that the total return of carton sheets and carton boxes exceeds the maximum limit set, with the main damage being rust. This study aims to control quality by implementing the PDCA (Plan, Do, Check, Action) method to reduce the return rate and increase production efficiency. The research method uses a qualitative descriptive approach with observation, interview, and documentation techniques. The analysis was carried out through a Pareto diagram to determine problem priorities, a cause-and-effect diagram (fishbone) to identify the main causes, and 5W + 1H and control charts for process evaluation and monitoring. The implementation results showed a significant decrease in the level of damage, especially for rust defects, after improvements were made to human, material, machine, method, and environmental factors. Key recommendations include operator training, evaluation of supplier governance assessments, routine machine maintenance, and updating of standard operating procedures (SOPs) to ensure continuous improvement and increase customer satisfaction.

Fulltext View|Download Email colleagues

Keywords: PDCA; Quality Control; Carton Packaging Returns; Continuous Improvement; Carton Packaging Industry

Article Metrics:

Article Info

Section: Original Research Articles

Language : EN

In 2026: JVSAR, Volume 8 Issue 1 Year 2026 (April 2026)

Andespa, I. (2020). Analisis Pengendalian Mutu dengan Menggunakan Statistical Quality Control (SQC) pada PT. Pratama Abadi Industri (JX) Sukabumi. E-Jurnal Ekonomi dan Bisnis Universitas Udayana, 9(2), 129–160. DOI: 10.24843/eeb.2020.v09.i02.p02
Assauri, S. (2016). Manajemen produksi dan operasi (Edisi revisi). Lembaga Penerbit Fakultas Ekonomi Universitas Indonesia
Gaspersz, V. (2008). Total quality management. PT Gramedia Pustaka Utama
Isniah, S., Purba, H.H., Debora, F. (2020). Plan do check action (PDCA) method: literature review and research issues. Jurnal Sistem dan Manajemen Industri, 4(1), 72–81. DOI: 10.30656/jsmi.v4i1.2186
Khama Ludin, K., Agustine, D., Harsadi, I., Juhara, S., Rahayu, M., Noviyanti, A., Permana, J. (2022). Upaya Meningkatkan Kemampuan Karyawan dalam Melakukan Continuous Improvement dengan Pelatihan Quality Control Circle (QCC) di Industri Manufaktur - Kawasan Industri Gajah Tunggal. Journal of Community Service and Engagement, 2(01), 5–11
Lodgaard, E., Powell, D. (2021). The changing role of shop-floor operators in zero defect manufacturing. Procedia CIRP, 104, 594–599. DOI: 10.1016/j.procir.2021.11.100
Purnomo, E.H., Rambe, I.M. (2021). Implementasi Dokumen Mutu untuk Penurunan Cacat Produksi Sambal Andaliman dalam Botol. Jurnal Mutu Pangan Indonesian Journal of Food Quality, 8(1), 17–24. DOI: 10.29244/jmpi.2021.8.1.17
Purwadi, P., Syaharuddin, Y., Sampeliling, A. (2020). FMEA Approach of Lean Sig Sigma Implementation: Estimating the Value of COPQ. International Journal of Psychosocial Rehabilitation, 24(3), 5592-5602. DOI: 10.61841/jp567861
Samuel, R., Rajesh, M., Rajanna, S., Franklin, E. (2021). Implementation of lean manufacturing with the notion of quality improvement in electronics repair industry. Materials Today Proceedings, 47, 2253–2257. DOI: 10.1016/j.matpr.2021.04.200
Sharma, M., Sharma, S., Sahni, S. (2020). Structured problem solving: combined approach using 8d and six sigma case study. Engineering Management in Production and Services, 12(1), 57–69. DOI: 10.2478/emj-2020-0005
Supriyadi, E. (2022). Analisis Pengendalian Kualitas Produk dengan Statistical Process Control (SPC). Tangerang: Pascal Books
Van Assen, M.F. (2020). Training, employee involvement and continuous improvement – the moderating effect of a common improvement method. Production Planning & Control, 32(2), 132–144. DOI: 10.1080/09537287.2020.1716405

Last update:

No citation recorded.

Last update:

No citation recorded.

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.

Journal Author(s) Rights

Authors who publish in the Journal of Vocational Studies on Applied Research (JVSAR) retain full copyright ownership of their work. In keeping with the journal’s commitment to open access, all articles are published under the terms of the Creative Commons Attribution-ShareAlike 4.0 International License (CC BY-SA 4.0).

This license permits anyone to access, use, share, adapt, remix, transform, and build upon the work for any purpose, including commercial use, provided that appropriate credit is given to the original author or authors, a link to the license is provided, changes to the work (if any) are clearly indicated, and any derivative works are distributed under the same license.

Authors are encouraged to disseminate their work as widely as possible. They retain the right to reuse their published article in future scholarly works, such as books, conference presentations, or teaching materials. They may also deposit the final published version in institutional or subject-based repositories, and share it freely on personal websites, academic platforms, or professional networks. These rights are fully preserved under the CC BY-SA license, and all such uses must comply with its terms.

Readers and third parties may also use the content in accordance with the CC BY-SA license. This includes the ability to reproduce, modify, and build upon the article, even for commercial purposes, as long as proper attribution is given, and any resulting work is distributed under the same license.

License to Publish Agreement (Non-Exclusive License for Publishing Rights)

To enable publication and global dissemination of accepted manuscripts, the Journal of Vocational Studies on Applied Research (JVSAR), published by Vocational College of Universitas Diponegoro, requires that authors grant the publisher a non-exclusive license to publish the work. This license authorizes the publisher to reproduce, distribute, and communicate the article to the public in all forms and media. The license to publish does not transfer copyright; authors remain the sole copyright holders.

This arrangement is formalized through a License to Publish Agreement, which the corresponding author must complete after the manuscript is accepted for publication. The agreement confirms that the author or authors grant the publisher the non-exclusive right to publish the article and to distribute it under the Creative Commons Attribution-ShareAlike 4.0 International License (CC BY-SA 4.0).

Authors retain all other rights to their work. They remain free to use and share their article in any manner consistent with the terms of the CC BY-SA license, including in future publications, educational settings, and commercial applications, provided proper attribution is given and the license is preserved.

After acceptance, the corresponding author will receive an email containing instructions for completing and electronically signing the License to Publish Agreement. The signed agreement must be returned to the Editorial Office in order to proceed with publication. The License to Publish Agreement form is available for download on the journal’s official website.

The non-exclusive Copyright Transfer Agreement for Publishing (CTAP) Form can be downloaded here: [Copyright Transfer Agreement for Publishing (CTAP) Form JVSAR 2025]

The (non-exclusive) publishing right form should be signed electronically and sent to the Editorial Office in the form of original e-mail below:

Dr.Eng. Vita Paramita (Editor-in-Chief)
Editorial Office of Journal of Vocational Studies on Applied Research
Vocational College of Universitas Diponegoro
Jl. Gubernur Mochtar, Tembalang, Semarang, Central Java, Indonesia 50275
E-mail: jvsar[at]live.undip.ac.id