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 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.

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 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 Defect Proses Produksi Songkok Berbasis Metode FMEA Dan FTA di Home - Industri Songkok GSA Lamongan

2021 ◽  
Vol 6 (3) ◽  
Author(s):  
Ayu Lestari ◽  
Nina Aini Mahbubah
Keyword(s):  
Product Quality ◽  
Failure Mode ◽  
Fault Tree ◽  
Fault Tree Analysis ◽  
Safety Net ◽  
Risk Priority Number ◽  
Human Errors ◽  
Effect Analysis ◽  
Good Material ◽  
Regular Training

Small and Medium sized enterprises are recognized as national safety net during crisis era in this nation. Gangsar is a small-sized enterprise and recognized as songkok home industry in Lamongan City. Maintaining sustainable quality is known as both challenge and weakness in order to sustain its business. The research purpose is to identify defect and analyze it in order to improve product quality. Failure Mode and Effect Analysis and Fault Tree Analysis were used as research method.  This research begun with mapping flow production process in order to identified defect product. Once defect product was recognized, the next stage was calculating risk priority number. Mapping fault tree was the next stage to detect failure mode. The results showed three defects identified namely trimmed with Risk Priority Number144, disorderly sewing process with RPN 126 and non-precision cutting fabric with RPN 86. These defects have been analyzed using FTA and it was found factors such as human errors, no-good material, and broken sewing machines need to be eliminated. Improving work facilities and regular training as well as working supervision are considered as better scenario in order to sustaining product quality.

scholarly journals Failure Mode and Effect Analysis (FMEA) for confectionery manufacturing in developing countries: Turkish delight production as a case study

2012 ◽  
Vol 32 (3) ◽  
pp. 505-514 ◽  
Author(s):  
Sibel Ozilgen
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Chemical Contamination ◽  
Risk Priority Number ◽  
Analysis Model ◽  
Production Potential ◽  
Effect Analysis ◽  
Potential Failure

The Failure Mode and Effect Analysis (FMEA) was applied for risk assessment of confectionary manufacturing, in whichthe traditional methods and equipment were intensively used in the production. Potential failure modes and effects as well as their possible causes were identified in the process flow. Processing stages that involve intensive handling of food by workers had the highest risk priority numbers (RPN = 216 and 189), followed by chemical contamination risks in different stages of the process. The application of corrective actions substantially reduced the RPN (risk priority number) values. Therefore, the implementation of FMEA (The Failure Mode and Effect Analysis) model in confectionary manufacturing improved the safety and quality of the final products.

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 Strategi Mitigasi Risiko Produktivitas Pada Proses Assembly Hospital Equipment

2021 ◽  
Vol 5 (1) ◽  
pp. 17
Author(s):  
Andrie Pasca Hendradewa ◽  
Adienta Mustika Ma'arij
Keyword(s):  
Quality Control ◽  
Failure Mode ◽  
Rapid Development ◽  
Value Added ◽  
Operating Table ◽  
Effect Analysis ◽  
Assembly Unit ◽  
Increase Productivity ◽  
Fmea Method ◽  
Hospital Equipment

The rapid development of technology and industrialization demands an increasing need for strategic planning. One of the strategies needed for a company to remain competitive in the industrialized world is to increase productivity. However, practically several companies still experience difficulties in making efforts to increase productivity so that the productivity achieved is not optimal. The same thing happened at PT. Mega Andalan Kalasan, especially on the Assembly Unit of the Hospital Equipment. Where the productivity achieved cannot be categorized as optimal because it can be seen from the number of non-value added activities that occur in assembly process. Among the products produced, it is known that the Operating Table Manual product has the highest percentage of non-value added activity, which is 30% of the total cycle time. This study aims to identify risks using the Failure Mode and Effect Analysis (FMEA) method and design a mitigation strategy as an initial effort to improve productivity by minimizing non-value added activities. The identification results show that there are 22 risks with moderate severity but high occurrence. Recommendations in the form of implementing better quality control on incoming materials are one of the strategies which capable of mitigating 40% of the risk of existing non value added activities. Adanya perkembangan teknologi dan industrialisasi yang semakin pesat menuntut kebutuhan akan perencanaan strategi semakin meningkat. Salah satu strategi yang dibutuhkan agar sebuah perusahaan dapat tetap bersaing di dunia perindustrian adalah dengan meningkatkan produktivitas. Namun pada penerapannya, beberapa perusahaan masih mengalami kesulitan dalam melakukan upaya peningkatan produktivitas sehingga produktivitas yang dicapai belum optimal. Hal yang serupa terjadi di PT. Mega Andalan Kalasan, khususnya pada lantai kerja Assembly unit Hospital Equipment. Dimana produktivitas yang dicapai belum bisa dikatakan optimal karena terlihat dari banyaknya non value added activity yang terjadi pada proses assembly. Diantara sejumlah produk yang dihasilkan, diketahui bahwa pengerjaan produk Operating Table Manual memiliki persentase non value added activity yang tertinggi yaitu sebanyak 30% dari total waktu siklusnya. Penelitian ini bertujuan untuk mengidentifikasi risiko dengan menggunakan metode Failure Mode and Effect Analysis (FMEA) dan merancang strategi mitigasi sebagai upaya awal untuk memperbaiki produktivitas dengan meminimalisir aktivitas non value added. Hasil identifikasi menunjukkan terdapat 22 risiko dengan tingkat severity sedang namun memiliki occurence yang tinggi. Rekomendasi berupa penerapan quality control yang lebih baik terhadap incoming material menjadi salah satu strategi yang mampu memitigasi 40% risiko aktivitas non value added yang ada.

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 Mode and Effect Analysis in Automotive Industry: A Case Study

2019 ◽  
Vol 19 (2) ◽  
pp. 10-15
Author(s):  
L. Petrescu ◽  
E. Cazacu ◽  
Maria-Cătălina Petrescu
Keyword(s):  
Failure Mode ◽  
Automotive Industry ◽  
Failure Modes ◽  
Action Plan ◽  
Electronic Devices ◽  
Area Network ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Iso 26262

AbstractNowadays, Failure Mode and Effect Analysis (FMEA) is more present in any standard evaluation of a product or process. In automotive industry, the IEC 61508 Standard adapted the ISO 26262 restrictions for Electrical and Electronic Devices. Conducting an FMEA reduces the costs by focusing on preventing failures, improving safety and increasing customer satisfaction. This paper presents a case study of a FMEA on a CAN (Controller Area Network) Bus Harness considering the entire process from defining the scope and building the team, to the action plan that will reduce the Risk Priority Number below the acceptable risk value. Also, the brainstorming that identifies the possible failure modes is presented.

Sign in / Sign up

Export Citation Format

Share Document