Pengendalian Kualitas untuk Menurunkan Defect Produk Pipe Brake Menggunakan Metode Seven Tools dan FMEA dengan Pendekatan Kaizen di PT. XYZ

Alan Fadlianto; Hana Silvia Dwi Putri; Fibi Eko Putra

doi:10.55606/jcsr-politama.v4i2.6467

Authors

Alan Fadlianto Universitas Pelita Bangsa
Hana Silvia Dwi Putri Universitas Pelita Bangsa
Fibi Eko Putra Universitas Pelita Bangsa

DOI:

https://doi.org/10.55606/jcsr-politama.v4i2.6467

Keywords:

Defect, FMEA, Kaizen, Pipe Brake, Seven Tools

Abstract

This study aims to reduce the defect rate of pipe brake products at PT. XYZ by integrating Seven Tools, Failure Mode and Effect Analysis (FMEA), and Kaizen methods. Based on identification using check sheets and Pareto diagrams, five main types of defects were found, where "uninstalled clips" were the most dominant, contributing 48%, followed by leaking pipes (21%) and dented pipes (15%). FMEA analysis revealed that the failure cause with the highest risk, indicated by the highest Risk Priority Number (RPN) score of 378, was the absence of an automatic control system in the clip installation process. Other contributing factors included inadequate brazing machine maintenance, lack of material handling standards, and weak quality control from suppliers. Through the Kaizen approach using 5 Whys and 5W+1H analysis, this research formulated technical improvement proposals such as the implementation of poka-yoke (error-proofing) systems, revision of Standard Operating Procedures (SOP), routine maintenance schedules, and visual control-based inspection systems. The implementation of these strategies is intended to reduce the initial defect ratio of 2.18% to a minimum level to achieve sustainable quality improvement in the production line.

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