scholarly journals Analysis and Defect Improvement Using FTA, FMEA, and MLR Through DMAIC Phase: Case Study in Mixing Process Tire Manufacturing Industry

2021 ◽  
Vol 54 (5) ◽  
pp. 721-731
Author(s):  
Tubagus Hendri Febriana ◽  
Hasbullah Hasbullah
Keyword(s):  
Manufacturing Industry ◽  
Fault Tree Analysis ◽  
Added Value ◽  
Mixing Process ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Tree Analysis ◽  
Industry Competition ◽  
Dmaic Method

In line with the increasingly fierce industry competition, all companies strive to make continuous improvements to increase added value and reduce waste which will impact the company's ability to maintain its existence in the future. One of the problems found in the tire manufacturing industry is the quality problem of the occurrence of defects in the mixing process which is dominated by the viscosity out standard on the compound steel breaker. In this study, analysis and improvement of the defect problem were carried out using Fault Tree Analysis (FTA), Failure Mode and Effect Analysis (FMEA), and Multiple Linear Regression (MLR) to test the correlation between the root causes found to the main problem. Based on the results of the analysis found thirteen root causes where the factor of variation in material viscosity and the suitability of determining the design process has the largest Risk Priority Number (RPN) value and has a strong correlation to defects that occur based on hypothesis testing. Furthermore, improvements are made using the DMAIC method on all factors that affect the occurrence of defects. As the result, the improvement can be effective in reducing the defect to 34.5% and achieve the expected target.

scholarly journals Implementation of Failure Mode and Effect Analysis and Fault Tree Analysis in Paper Mill: A Case Study

2020 ◽  
Vol 9 (3) ◽  
pp. 171-176
Author(s):  
Nurul Retno Nurwulan ◽  
Wilcha Anatasya Veronica
Keyword(s):  
Quality Control ◽  
Failure Mode ◽  
Fault Tree Analysis ◽  
Paper Mill ◽  
Control Methods ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Increase Productivity ◽  
Prevention Methods

A good quality control system is important to be implemented to increase productivity and minimize defects in products. One of the quality control methods is failure mode and effect analysis (FMEA). This study uses the FMEA to identify the causes of the defects and recommend the prevention methods to overcome the causes of the defects in an Indonesian paper mill. The risk priority number (RPN) is calculated by multiplying the severity, occurrence, and detection of the failures that have been determined. Unsymmetrical and tainted products are the most dominant defects in the paper mill. An inappropriate machine setting is the cause of unsymmetrical products with the highest RPN of 343. The second highest RPN is problems with bleaching machines that caused tainted products with an RPN value of 216. This study offers suggestions to Indonesian paper mill to prevent and minimize defective products. 

scholarly journals Analisis Pengendalian Mutu pada Proses Produksi Pembuatan Kecap Menggunakan Metode Fault Tree Analysis (FTA) dan Metode Failure Mode Efect Analysis (FMEA)

2020 ◽  
Vol 1 (1) ◽  
pp. 31-44
Author(s):  
Iskandar Zulkarnaen ◽  
Daonil ◽  
Akbar Supriadi
Keyword(s):  
Failure Mode ◽  
Fault Tree ◽  
Fault Tree Analysis ◽  
Soy Sauce ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Tree Analysis ◽  
Mode Effect ◽  
Fmea Method ◽  
Failure Mode Effect Analysis

ABSTRACT Analysis of Quality Control in the Production Process of Making Soy Sauce Using the Fault Tree Analysis (FTA) Method and the Failure Mode Effect Analysis (FMEA) Method. PT XYZ is an industrial company that produces soy sauce and soy sauce for instant noodle seasoning. In an effort to maintain product quality, the writer tries to analyze every problem of reject burn, reject divert, organoleptic reject, and contaminated reject that exceeds the company standard of 0.50% based on histogram data for May 2018 - April 2019, it is found that organoleptic reject is the highest failure and the main problem is discussed using the fault tree analysis (FTA) method to analyze the root cause of failure, and the failure mode effect analysis (FMEA) method for weighting the severity, occurance and detection values ​​in each of these three issues each problem is calculated to obtain a risk priority number (RPN) value ). From this data, it will be known that the root of the problem is the steam engine temperature value of 144 is the highest value of rpn, and the writer tries to give a proposal to improve the previous total reject 244,425 kg percentage 0.65% and after 69,284 kg percentage 0.36% with the cost before the total repair is Rp. 881,840,120 and after Rp.255,474,078 succeeded in reducing rejects below the standard while reducing costs for Rp.626,366,042. Keyword : Reject, Soy Sauce, FTA, FMEA ABSTRAK Analisis Pengendalian Mutu Pada Proses Produksi Pembuatan Kecap Menggunakan Metode Fault Tree Analysis (FTA) dan Metode Failure Mode Effect Analysis (FMEA). PT XYZ merupakan perusahaan industri yang menghasilkan produk kecap manis dan kecap asin untuk bumbu mie instant. Dalam upaya mempertahankan kualitas produk penulis berusaha untuk menganalisa setiap permasalahan reject gosong, reject divert, reject organoleptik, dan reject terkontaminasi yang melebihi standar perusahan 0,50% berdasarkan data histogram periode mei 2018 – april 2019 didapatkan reject organoleptik menjadi kegagalan tertinggi dan masalah utama yang dibahas dengan menggunakan metode fault tree analysis (FTA) untuk menganalisa akar penyebab kegagalan, dan metode failure mode effect analysis (FMEA) untuk pembobotan nilai severity, occurance dan detection di dalam ketiga hal tersebut setiap permasalah tersebut dihitung hingga mendapatkan nilai risk priority number (RPN). Dari data tersebut selanjutnya akan diketahui akar permasalahan tersebut adalah mesin steam suhu nilai 144 merupakan nilai rpn tertinggi, selanjutnta penulis mencoba memberikan usulan perbaikan sebelumnya total reject 244.425 kg persentase 0.65% dan sesudah 69.284 kg persentase 0.36% denga biaya sebelum perbaikan total Rp. 881.840.120 dan sesudah Rp.255.474.078 berhasil menurunkan reject dibawah standar sekaligus menurunkan biaya pengeluran sebesar Rp.626.366.042. Kata Kunci : Reject, Kecap, FTA, FMEA

scholarly journals ANALISIS PENYEBAB KECACATAN PRODUK SEPATU TERREX AX2 GORETEX DENGAN MENGGUNAKAN METODE FAULT TREE ANALYSIS (FTA) DAN FAILURE MODE AND EFFECT ANALYSIS (FMEA) DI PT.PANARUB INDUSTRI

2018 ◽  
Vol 3 (1) ◽  
Author(s):  
Joko Supono
Keyword(s):  
Failure Mode ◽  
Fault Tree ◽  
Fault Tree Analysis ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Tree Analysis

Produk cacat merupakan barang atau jasa yang dibuat dalam proses produksi namun memiliki kekurangan yang menyebabkan nilai atau mutunya kurang baik atau kurang sempurna. PT. Panarub Industry adalah salah satu perusahaan yang bergerak di bidang manufaktur, khususnya sepatu Adidas. Plant 5 cell 1 adalah plant yang memproduksi sepatu jenis outdoor, salah satunya yaitu sepatu model Terrex AX2 Goretex yang mempunyai tingkat kegagalan produk sebesar 13,65% pada proses produksi dan ini melebihi dari toleransi kegagalan yang ditetapkan perusahaan sebesar 3%, sehingga perlu dilakukan perbaikan untuk mengurangi jumlah kecacatan produk pada tiap proses produksi. Metodologi penelitian yang dilakukan untuk pemecahan masalah yaitu dengan Fault Tree Analysis (FTA) untuk mengidentifikasi penyebab kecacatan produk berdasarkan proses produksi saat ini, tahapan selanjutnya dengan menggunakan Failure Mode and Effect Analysis (FMEA) untuk mengidentifikasi potensi failure mode, potensi efek kegagalan, penyebab kegagalan, mode-mode deteksi, dan menentukan rating terhadap severity, occurance,dan detection pada risk priority number pada proses produksi. Berdasarkan hasil dari penilaian pada RPN, didapatkan proses sewing dengan skor 576, dan assembling 512 dengan skor 512 mendapatkan nilai RPN tertinggi dan mempunyai tingkat kecacatan mayor. Usulan perbaikan untuk Cacat sewing dengan melakukan pengawasan, training, dan pengecekan mesin secara berkala, penggunaan jarum sesuai standar. Cacat assembling dengan pemeriksaan, pengawasan, penggantian peralatan, dan pengecekan mesin secara berkala. Dengan menerapkan usulan tersebut diharapkan dapat menurunkan tingkat kecacatan produk.

scholarly journals ANALISIS PENYEBAB KEGAGALAN PENGIRIMAN BARANG PROJECT 247 ATAU JENIS SXQ PADA DIVISI OPERATION AIRFREIGHT PT.CIPTA KRIDA BAHARI DENGAN METODE FAILURE MODE AND EFFECT ANALYSIS (FMEA) DAN FAULT TREE ANALYSIS (FTA)

2021 ◽  
Vol 11 (1) ◽  
pp. 7-13
Author(s):  
Achmad Andriyanto ◽  
Yuniar Ega Anggraini Putri
Keyword(s):  
Failure Mode ◽  
Fault Tree ◽  
Fault Tree Analysis ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Tree Analysis

PT. Cipta Krida Bahari (CKB Logistics Group) merupakan badan usaha penyedia solusi dari rantai pasok untuk memenuhi kebutuhan dari pelanggan dengan dukungan keterampilan dan pengalaman di bidang logistik. Pada PT. Cipta Krida Bahari Cabang Surabaya terdapat beberapa kegagalan pengiriman barang jenis SXQ, hal ini tentu berdampak pada perusahaan yaitu kepercayaan customer dalam menggunakan jasa PT. CKB akan berkurang, melihat adanya permasalahan ini penulis tertarik untuk melakukan penelitian terhadap kegagalan pengiriman barang jenis SXQ di PT. Cipta Krida Bahari Cabang Surabaya. PT. Cipta Krida Bahari membutuhkan solusi dalam penanganan masalah tersebut dengan menggunakan metode Failure Mode and Effect Analysis (FMEA) untuk mencari prioritas penyelesaian permasalahan dalam sistem. Penentuan prioritasnya didasarkan pada nilai Risk Priority Number (RPN) dari setiap permasalahan. Sedangkan Fault Tree Analysis (FTA) untuk mencari kombinasi dari kejadian penyebab kerusakan dalam sistem. Berdasarkan hasil metode FMEA terdapat 2 potential cause yang masuk dalam kategori 80% total persentase kumulatif yang kemudian diidentifikasi lebih mendalam dengan menggunakan metode FTA. Potential cause yang akan diidentifikasi menggunakan metode FTA adalah keterlambatan pembuatan manifest dan PTI serta keterlambatan serah terima barang dari bagian warehouse.

scholarly journals Analisis Defect dengan Metode Fault Tree Analysis dan Failure Mode Effect Analysis

2019 ◽  
Vol 2 (2) ◽  
pp. 62-72
Author(s):  
Evan Nugraha ◽  
Rini Mulyani Sari
Keyword(s):  
Production Process ◽  
Failure Mode ◽  
Fault Tree ◽  
Fault Tree Analysis ◽  
Analysis Method ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Tree Analysis ◽  
Mode Effect ◽  
Failure Mode Effect Analysis

There was a phenomenon that occurred in garment companies, namely the existence of defect products in the production process. In the sewing process, defects occurred with an average percentage of 6,67% in the first three months of early 2019. This 6,67% was a percentage of disability that exceeded the company percentage limit of 5%, thus disrupting the production process. The primary purposed of analyzing the factors of product defects was to find out the causes and solutions to the company. The Fault Tree Analysis method was used to find out the root caused of product defects. Three main problems caused product defects, namely 1) untidy stitches, 2) stitches that exceeded the specified size, and 3) straightened stitches. By using the Failure Mode Effect Analysis method, the three problems were caused by human error and the absence of a Standard Operating Procedure in the production process. As a solution to problems in the company, the Risk Priority Number value was used. From this study the result obtained 1 Risk Priority Number value is the proposed improvement.

scholarly journals FAILURE RISK ANALYSIS GLASS BOWL PRODUCTION PROCESS USING FAILURE MODE EFFECT ANALYSIS AND FAULT TREE ANALYSIS METHODS (A CASE STUDY)

JOURNAL ASRO ◽  
2018 ◽  
Vol 9 (2) ◽  
pp. 1
Author(s):  
Ikhwan Syahtaria ◽  
Ali Mashudi ◽  
Bambang Suharjo
Keyword(s):  
Production Process ◽  
Failure Mode ◽  
Fault Tree ◽  
Fault Tree Analysis ◽  
Total Production ◽  
Effect Analysis ◽  
Tree Analysis ◽  
Fmea Method ◽  
Glass Bowl

Product defects are a natural thing in a production process, but it would be better to avoid them. XYZ Industries is a company that produces glassware in the form of the glass bowl. The production failure experienced by this company is still high at 3.1% of the total production while the defect target that the company wants is 2%. The purpose of this study was to identify the types of defects that occur in glass bowl products on the production floor based on the results of searches of literature studies and deep interviews with employees, get the risk of failure of the largest production process in the RPN (Risk Priority Number) value of the FMEA method then analyzed again using the FTA method and determine the proposed improvements needed based on the analysis of defects that occur in glass bowl products, thus minimizing product defects and increasing company profits. In this study using the method of Failure Mode and Effect Analysis (FMEA) and the Fault Tree Analysis (FTA) method to identify failures that occur and provide prevention solutions. Based on the results of data processing, the proposed improvements given to the company as a whole are the company in order to pay more attention to the maintenance of the machine so that the machine can avoid the failure of its function

scholarly journals Risk analysis of production process for food SMEs using FMEA method: a case study

2021 ◽  
Vol 331 ◽  
pp. 02010
Author(s):  
Prima Fithri ◽  
Muhammad Rafi ◽  
Pawenary ◽  
A. S. Prabuwono
Keyword(s):  
Human Resources ◽  
Production Process ◽  
Critical Value ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Increase Productivity ◽  
Fmea Method ◽  
Bread Production ◽  
A Company

The increasing development of the industry makes every industry have to compete with other competitors to gain an edge. The advantages of competition are influenced by several factors, one of which is good human resource management. Where if a company has good human resources, it will increase profits indirectly and can increase productivity. This research discusses case studies about the potential dangers of IKM Heppy Bakery’s potential dangers that can harm workers in bread production. The method used is Failure Mode And Effect Analysis (FMEA). Later, the data will be filled and given a rating distinguished into three parts: severity, occurrence, and detection. The data were obtained through questionnaires given to 3 workers at IKM Heppy Bakery and filled in rating values based on the provisions that have been given to the questionnaire. This Value helps determine the Risk Priority Number (RPN) obtained from multiplication between severity, occurrence, and detection. After processing the RPN multiplication data, the highest RPN value was obtained by 193 with the danger factor of the operator overheating and dehydrating due to high temperatures. Furthermore, the calculation of critical Value was obtained by 109. Based on the critical Value obtained seven hazard factors above the critical value, these seven hazard factors need to be improved so that workers do not avoid accidents when conducting the production process.

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