Reduction of Visual Defects Dented in Valve Seat Products Using the Failure Mode and Effect Analysis (Fmea) Method and Kaizen Seven Tools at PT. XYZ

Muh Rosyid; Fibi Eko Putra; Tri Ngudi Wiyatno

Authors

Muh Rosyid Universitas Pelita Bangsa
Fibi Eko Putra Universitas Pelita Bangsa
Tri Ngudi Wiyatno Universitas Pelita Bangsa

Keywords:

Product Defect, Seven Tools, FMEA, Quality Control

Abstract

XYZ is one of the manufacturing companies that produces precision spare parts for automotive and electronic components. One of the automotive component spare parts is the Valve Seat. In the production process, there are NG (Not Good) valve seat products that are delivered to customers, resulting in frequent customer claims. This research aims to describe and analyze work process improvements so that quality can be maintained using the Seven Tools Method and to identify the factors causing the delivery of non-conforming products. Furthermore, the Failure Mode and Effect Analysis method is used to identify the highest failure risks, followed by kaizen implementation. Based on these results, an analysis of work process improvements is required to maintain product quality before delivery to customers by creating work instructions and adding work process methods during handling. Based on the pareto defect diagram, the most frequent defect in the last 3 months was the dented part, accounting for 95,91%. The contributing factors were: Human factors, where operators did not yet fully understand handling requirements; machine factors, where components and cutting oil circulation were dirty; method factors, where handling was not in accordance with SOP; and material factors, where the material made of stainless steel was easily scratched. By implementing FMEA and Kaizen, it was found that the Valve Seat production process at PT XYZ was already quite good, with a defect reduction of 0.87%, from the previous defect rate of 2.75% to 1.88%.

References

J. Hasil, P. Dan, K. Ilmiah, A. Wicaksono, E. Dhartikasari Priyana, dan Y. P. Nugroho3, “Analisis Pengendalian Kualitas Menggunakan Metode Failure Mode and Effects Analysis (FMEA) Pada Pompa Sentrifugal Di PT. X.”

A. Muhazir, Z. Sinaga, dan A. A. Yusanto, “Analisis Penurunan Defect Pada Proses Manufaktur Komponen Kendaraan Bermotor Dengan Metode Failure Mode And Effect Analysis (FMEA),” 2020. [Daring]. Tersedia pada: http://journal.uta45jakarta.ac.id/index.php/jktm/index

F. Rachmania Supoyo dan R. Achmad Darajatun, “Analisis Pengendalian Kualitas Untuk Mengu-rangi Defect Parking Brake dengan Metode FMEA di PT XYZ,” vol. VIII, no. 1, 2023.

M. Abdurrahman, A. W. Rizqi, dan M. Jufriyanto, “Pengendalian Kualitas Kayu Kering pada Mesin Kiln Dryer untuk Mengurangi Produk Cacat dengan Metode Seven Tools dan Failure Mode Effect Analysis,” vol. VIII, no. 4, 2023.

A. Rizky, H. Saputra, J. Sagala, dan I. Kurnia, “ANALISIS PENGENDALIAN KUALITAS DI LINE DOOR MIRROR DALAM UPAYA MENURUNKAN RASIO PART REJECT DENGAN METODE FMEA,” Jurnal, vol. 12, no. 2, 2023.

W. Safitri, D. M. Fahreza, P. Manajemen, F. Ekonomi, D. Bisnis, dan U. Pelita Bangsa, “Jurnal Pelita Manajemen Analisis Product Defect dengan Metode Seven Tools dan FMEA.”

P. Wisnubroto dan A. Rukmana, “PENGENDALIAN KUALITAS PRODUK DENGAN PENDEKA-TAN SIX SIGMA DAN ANALISIS KAIZEN SERTA NEW SEVEN TOOLS SEBAGAI USAHA PEN-GURANGAN KECACATAN PRODUK,” 2015.

T. N. Wiyatno, H. Kurnia, I. M. M. Putri, dan R. Nugroho, “The combination of the kaizen approach with the Design of Experiment (DoE) method for improving quality of the bread and donut prod-ucts in SMEs,” OPSI, vol. 17, no. 1, hlm. 12, Jun 2024, doi: 10.31315/opsi.v17i1.11108.

H. Rizqya Ardyansyah dan N. Utami Handayani, “ANALISIS PENGENDALIAN KUALITAS PRODUK KAIN GREY PS 946 DALAM UPAYA MENGURANGI TINGKAT KECACATAN PRODUK MENGGUNAKAN METODE FAILURE MODE AND EFFECT ANALYSIS (FMEA) DAN PENDEKA-TAN KAIZEN (STUDI KASUS PT. PRIMISSIMA).”

V. Nur’Aini dan D. Andesta, “Analisis Pengendalian Kualitas Produksi Papan Fiber Semen dengan Metode Seven Tools dan FMEA pada PT. XYZ,” G-Tech: Jurnal Teknologi Terapan, vol. 8, no. 2, hlm. 1166–1173, Apr 2024, doi: 10.33379/gtech.v8i2.4162.

Y. Syahrullah, D. Milenia, dan R. Izza, “INTEGRASI FMEA DALAM PENERAPAN QUALITY CON-TROL CIRCLE (QCC) UNTUK PERBAIKAN KUALITAS PROSES PRODUKSI PADA MESIN TENUN RAPIER,” 2021.

F. Farchiyah, “ANALISIS PENGENDALIAN KUALITAS SPANDUK DENGAN METODE SEVEN QUALITY CONTROL TOOLS (7 QC) PADA PT. FAJAR INTERPRATAMA MANDIRI (FIM PRINT-ING).”

A. Tyaz Nugraha, L. Afriani, dan R. Wahyudi, “Pengendalian Kualitas Dengan Pendekatan Metode Statistical Process Control, FMEA, Dan Kaizen Di PT. Surya Tsabat Mandiri.” [Daring]. Tersedia pada: http://jurnal.utu.ac.id/invasi/

B. S. Wijaya, D. Andesta, dan E. D. Priyana, “Minimasi Kecacatan pada Produk Kemasan Kedelai Menggunakan Six Sigma, FMEA dan Seven Tools di PT. SATP,” Jurnal Media Teknik dan Sistem Industri, vol. 5, no. 2, hlm. 83, Sep 2021, doi: 10.35194/jmtsi.v5i2.1435.

D. Chandrahadinata dan W. Nurdiana, “Analisis Pengendalian Kualitas pada Crude Palm Oil un-tuk Meningkatkan Kualitas di PT. Condong Garut.” [Daring]. Tersedia pada: https://jurnal.itg.ac.id/