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XYZ is a company operating in the textile industry and producing rayon fabric. In the production process, defects were still found in the period October 2023 – March 2024. Rayon fabric production was 286973m, consisting of defects in final weft 11643m, wavy 8391m, unwoven 7569m, double weft 6173m, stretch weft 8126m. Based on the problem, it can be solved using the six sigma method and FMEA with the DMAIC stage used to control quality from the initial process until a proposal for improvement is found. Obtained from the calculation results, the average sigma is 3.39 with an average DPMO of 29046.87 in production approval. The Pareto diagram of the most dominant defect percentages is final weft defects 27.8%, wavy 20.0%, loose weft 19.4%, non-woven 18.1%, double weft 14.7%. The highest RPN value was 280 for final feed defects and waves caused by workers' lack of accuracy regarding machine settings. Intensive training, process standardization, performance monitoring, use of checklists, increased communication, routine maintenance, use of technology..

XYZ is a company operating in the textile industry and producing rayon fabric. In the production process, defects were still found in the period October 2023 – March 2024. Rayon fabric production was 286973m, consisting of defects in final weft 11643m, wavy 8391m, unwoven 7569m, double weft 6173m, stretch weft 8126m. Based on the problem, it can be solved using the six sigma method and FMEA with the DMAIC stage used to control quality from the initial process until a proposal for improvement is found. Obtained from the calculation results, the average sigma is 3.39 with an average DPMO of 29046.87 in production approval. The Pareto diagram of the most dominant defect percentages is final weft defects 27.8%, wavy 20.0%, loose weft 19.4%, non-woven 18.1%, double weft 14.7%. The highest RPN value was 280 for final feed defects and waves caused by workers' lack of accuracy regarding machine settings. Intensive training, process standardization, performance monitoring, use of checklists, increased communication, routine maintenance, use of technology..

LP is one of the pharmaceutical companies located in Serang, Banten. The production of the company is tablets, capsules, and syrup. Problems that occur at PT. LP is a product defect that occurs in capsule filling, especially in capsule A. The purpose of this study is to determine the defective products that occur in capsule A and to find out the proposed improvements that will be made to reduce product defects in capsule A. The research methods used are Statistical Process Control (SPC)  and Fuzzy Failure Mode and Effect Analysis (F-FMEA). The population and samples used were defective capsule A during the production process from March 2022 to May 2023, with sampling techniques through production data, observation and interviews. And the results of research using a check sheet show that the percentage of defects reaches 6%, based on the pareto chart, the priority of improvement that needs to be done is for the dominant type of defect, namely  the dented capsule reject reaches 90%, and on the control chart there are still control points that are outside the UCL and LCL. FMEA calculations, the RPN value of the capsule is dented on the head of the capsule or capsule body reaches 384, and the FRPN value is 6.76.    

CV Harico is a manufacturing company that produces briquetted charcoal final products. In this research, the company had problems with the quality of charcoal briquettes which did not meet standards, amounting to 12% of the production process, including slanted shapes, holes and cracks. In this research, problem solving is done by combining the Six Sigma and TRIZ methods to get suggestions for improvement. The Six Sigma method is an organized and systematic method, Six Sgma has 5 stages, which can be known as the DMAIC phase. Based on the calculation of the DPMO value and the calculation of the sigma value at the measurement stage, the average DPMO value for October 2023-November 2023 was 27219 with a sigma value of 3.43. Based on the identification results using the Fishbone Diagram method and the FMEA method, the largest defects were found in the slanted shape of the charcoal briquettes, these results were obtained from the factor with the highest RPN value that caused defects. Proposed improvements based on the TRIZ method analysis include providing training, carrying out periodic actions, making maintenance schedules, evaluating work processes, changing tools to reduce the occurrence of defects. The aim of this research is to analyze the problems that occur as well as efforts to control quality and reduce product defects in briquetted charcoal products.

PT XXX is a garment company on an international scale. Technical staff plays an important role in maintaining operational performance, especially in facing challenges during rapid style changes and potential operational risks. This research aims to identify the causes of low productivity of technical staff performance, design improvement strategies with a focus on productivity improvement, and evaluate the effectiveness of the Failure Mode and Effect Analysis (FMEA) method in improving the technical performance of technical staff. The results of this research show that the FMEA method is effective in identifying potential failures, helps evaluate the level of risk by calculating the Risk Priority Number (RPN) value, and is a reliable tool for designing strategies to improve technical staff performance.

PT The lathe is one of the essential machines in production activities in this company. The amount of downtime caused by machine failure will reduce product quality and quantity. Therefore, this research aims to identify the factors that most influence the risk of lathe failure so that repair priorities and maintenance strategies can be determined. This can be achieved by using the Failure Mode and Effect Analysis (FMEA) method. FMEA is a method that can be used to identify the causes and impacts of each possible failure mode on machine components by systematically explaining the levels of failure so that appropriate prevention or repair can be carried out. The FMEA method shows the Risk Priority Number (RPN) value as a reference in determining the choice of maintenance strategy, namely, predictive maintenance, preventive maintenance or corrective maintenance. The research results show that the highest RPN value is found in the motor shaft pulley component at 320 and Nut Screw at 210. Maintenance priorities are determined based on the Pareto diagram principle. The appropriate maintenance strategy carried out by PT.   Keywords: FMEA, Lathe, Maintenance, RPN

This study aims to determine the number of rejected products (products that do not meet consumer and company standards) for 220 mL cup products using the six sigma method with 5 stages (define, measure, analyze, improve, and control) which will then be given improvement recommendations using failure mode effect analyze (FMEA). After going through the calculation process, it is known that the company's Deffect Per Million Opportunity (DPMO) value is 3.67 which indicates that the percentage of production without deffects is 96.32%. There are four critical to process (CTQ) in the 220 mL cup defect and the largest is the skewed seal with a percentage of 70%. The results of calculations using risk priority number (RPN) found recommendations in the form of corrective actions in 80% of the group of causes of oblique seal deffects so that it is hoped that the company will review and make improvements to the proposal so as to reduce deffects per million opportunity (DPMO) in the 220 mL cup production unit.                                                                                                      

Menurut data dari BPJS, kecelakaan kerja yang terjadi di Indonesia pada bulan Januari hingga November 2022 sebanyak 265.334 kasus. Jumlah ini meningkat 13,26 persen dibandingkan 234.270 kasus pada tahun 2021. Data tersebut menjadi peringatan keras bahwa pelaksanaan keselamatan dan kesehatan kerja (K3) harus semakin menjadi perhatian. UD Cantenan menggunakan beberapa mesin, bahan-bahan kimia dan suhu yang tinggi, dan hampir seluruh proses dilakukan masih secara manual tanpa alat bantu dan dioperasikan langsung. Berdasarkan obeservasi yang dilakukan terdapat 34 risiko kecelakaan kerja yang terdapat pada bagian proses produksi dan tercatat ada 14 kasus kecelakaan kerja yang terdapat pada bagian produksi di Ud Cantenan, data tersebut diambil dari bulan Febrari tahun 2020 hingga bulan Juli tahun 2023. Metode JSA digunakan untuk menentukan pekerjaan yang dianalisis serta mengidentifikasi risiko pada masing-masing pekerjaan, Metode FMEA difungsikan untuk mengidentifikasi tingkat risiko kecelakaan kerja yang mengukur dari aspek dampak, peluang kejadian dan pencegahaannya dilakukan, sedangkan metode FTA digunakan untuk mengdentifikasi potensi penyebab kecelakaan. Dari hasil analisis data diketahui bahwa 5 failure mode dengan nilai RPN terbesar yaitu, terkena tumpahan logam cair,, tergulung putaran chuck mesin turning, tersengat listrik, tergulung putaran mata pahat milling dan mata terkena sekrap logam sisa produksi, ke lima failure mode dengan nilai RPN tertinggi yaitu fm 14, fm 27, fm 31 dengan nilai RPN 75 dan fm 22, fm 28 dengan nilai RPN 64. Nilai RPN tertinggi nantinya akan dilakukan analisis FTA untuk mengetahui akar penyebab masalah dan diberikan rekomendasi untuk perbaikan, untuk FM 14, 21, dan 38 memiliki tiga akar masalah, sedangkan fm 27 dan 28 memiliki 4 akar masalah.

As innovation develops and the human population increases, product competition between companies increases, so producers are required to produce goods as quickly as possible while still considering the quality aspects of the product. PT. Cipta Oggi is a company engaged in furniture production. PT. Cipta Oggi has several types of production, namely office tables, cupboards, TV shelves and decorative cupboards. In the production process for the 2DF WHT polo showcase furniture product, it has the highest rework rate, namely 10.67%. The method used in this research is the FMEA method. The FMEA method will later produce output results in the form of an RPN from which recommendations for improvement will be obtained from the types of causes of failure that are the highest. With this research, the aim is to analyze the causes of rework in the production process of Polo Showcase 2DF WHT furniture products which can later reduce the rework rate.

Abstract. UD Cantenan is an industrial company engaged in metal casting, especially made from Aluminum. This company is known to have quality control problems in the manufacture of lip handle products and canal parts. The result of this problem is defective products in the lip handle and canal parts. In this case, of course, the company will spend more to repair the product so that the company experiences losses. Companies need to find ways to reduce the number of defective products. In this study, the Six Sigma method was used with DMAIC (Define, Measure, Analyze, Improve Control) and TRIZ stages to analyze and provide solutions to improve problems that occurred in the company. Based on the research conducted, at the define stage there are 3 types of defects in the lip handle product and canal parts, namely small scratches, small pinholes, and asymmetrical patterns. Then the measure stage obtained the percentage of small scratch defects of 54.47%, small pinholes of 17.3% and asymmetrical patterns of 28.2%. The average DPMO score obtained is 25,720 with a sigma level of 3.45 which shows that UD Cantenan can be categorized as good for industry in Indonesia. Furthermore, at the analysis stage Based on the identification of causal factors using FMEA analysis, it is known that the biggest contributing factor to failure is operator error in the operation of the milling machine. Then at the improve stage, make improvement proposals based on obtaining the highest RPN value from the factors causing disability using the TRIZ method. And the last stage, namely control, is the result of proposed improvements that can be made by the company to solve problems to reduce the number of product defects that occur during the production process.

. This research was conducted to analyze the quality of the coating process at PT Swadaya Graha using the Failure Mode Effects Analysis (FMEA) method. Primary and secondary data collection was carried out in this research. The research results showed that there were five types of defects, namely polishing marks, orange peel, dustpray, sagging and cracking. Based on the FMEA method, the defect rating is determined based on the resulting cumulative percentage value where the highest value is obtained for orange peel defects at 41.7%. This defect was analyzed and it was found that one of the causal factors was the incorrect application of the spreading rate. This factor is obtained from an RPN value of 120. From this research it can be concluded that the FMEA method can be used as a tool to minimize defects in the coating process and analyze improvements that should be prioritized..    

CV Dafista Mulia is a drinking water producer company located in Lamongan Regency. The problem that is often faced by companies is the amount of waste that occurs in the process of producing bottled drinking water. The most critical percentage of waste in the bottled water production process (AMDK) is waste overproduction with a weighting percentage of 25.4%; waste defet with a weighting percentage of 16.2%; waste inventory with a weighting percentage of 14.9%; waste unnecessary motion with a weighting percentage of 14.1%; waste transportation with a weighting percentage of 11.7%; waste waiting with a weighting percentage of 9%; and waste excess processing with a weighting percentage of 8.7%. The initial activity time before the repair was 466 minutes (7 Hours 46 Minutes) and after the repair was reduced to 416 minutes (6 Hours 51 Minutes). Based on the Failure Mode and Effect Analysis (FMEA), it is known that the root cause of the problem with the highest waste is Overproduction, namely production planning that is not quite right with a Risk Priority Number (RPN) score of 396. Recommendations for improvements that can be proposed are to carry out production planning using data - historical data that exists and is adjusted to balance the purchasing of raw materials with orders from consumers so that the results of the Overproduction can become a safety stock so that the Overproduction can function in the next consumer order.

PT Wahana Kasih Mulia is a PT engaged in the manufacture of baby equipment. In the production process, which uses a lot of machines and heavy equipment such as cutting machines, pressing machines, and sewing machines, there are potentials and hazards that can cause accidents to operators/employees. This research was conducted by measuring failure in every activity in PT. Wahana Kasih Mulia, measurements were made on every machine in the factory area. Data processing is done by calculating the failure rate, failure effect, incident rate, then determining the detection rate and calculating the RPN value to determine which priority should be taken using the Job Safety Analysis method. Research results There are work accidents at PT. Rides of Noble Love, Hands pierced by needles, Cuts by cutting machines, hands exposed Penulis 1./ Job Safety Analysis Sebagai Upaya Pengendalian Resiko Kecelakaan Kerja., Januari 2023 pp. 1-4 to electric presses, Eyes exposed to dacron dust, Fall of piles of finished materials, skin irritation from dacron dust, Breathing problems due to dirty dust. Proposed improvements that can be given are adding some personal protective equipment that is appropriate to the work and factory environment, operators must use safety glasses, face shields, mask earmuffs, safety gloves, safety shoes.

. In the shipbuilding industry, the repair process is a series of jobs that require a relatively short time. Delays in repairs can occur due to weak management and also caused by less than optimal empowerment of human resources. This study aims to identify the risks found in four divisions, namely the Production Division, Warehouse Division, Finance Division and Purchasing Division. The study found 31 risk events. Determining the value of each risk is carried out using the Failure Mode and Effect Analysis method. There were 13 risks that had the highest Risk Priority Number, namely the length of approval for requests for goods (RPN = 522.88), delays in payment processes by customers (RPN = 504.64), requests for additional work from the owner (RPN = 477.128), fluctuations in the number of manpower (RPN = 454.08), Changes in material use related to the availability of materials in the warehouse (RPN = 411.768), Changes in material calculations related to design (RPN = 389.017), Length of decision making by the owner (RPN = 388.36), Long material delivery process (RPN = 388.36), Insufficient stock material (RPN = 357,588), Writing the amount on the Request for Goods Bill is not detailed (RPN = 357.71), Lack of availability of stock material (RPN = 349,524), Making and submitting late payment requests (RPN = 316.8), Placement of materials that are less efficient (RPN = 296.8) Risk mitigation is carried out using the Fault Tree Analysis method to find the main cause / basic event of each risk. And the mitigation step that needs to be done is by making changes to the warehouse layout. If the layout design of the warehouse is changed to be more efficient it will speed up the material retrieval process which has an impact on the ship repair process time.

CV. XYZ is a manufacturing company whose main product is lightweight concrete bricks made in various sizes. Lightweight concrete brick with a thickness of 10 cm is the product that produces the highest defects compared to other products. The resulting defects have an average of 5% where this value exceeds the company's tolerance limit of 3-4%. Based on these problems, a study was conducted to determine the level of defects of lightweight concrete bricks and to provide suggestions for improvements to reduce defects. The research was conducted using the Seven Tools method and Failure Mode and Effect Analysis (FMEA). The results showed that the defect level of Lightweight Concrete Bricks from the highest to the lowest were chipped, cracked, uncut, and dimensional defects respectively. In addition, it can be seen that the Gompal failure mode with the cause of the disassembly or sorting process is too hard to produce the highest RPN score of 245, so that the recommendations for improvement need to be prioritized first.

CV Berkah Kecambah Tauge Aling is a company engaged in the field of food or vegetable bean sprouts made from green beans. In the production of CV Berkah Kecambah Tauge Aling there was a product defect in January 2023 which occurred, namely the result of the defect rate which was known to have the highest number of defects in the yellow color defect of 1818 packages, with a defect percentage of 58.3%. Then the Bad Smell defects with a total of 879 defects, a percentage of defects obtained by 28.2%, the type of defective packaging torn with a total of 423 defects, a percentage of defects of 13.6%. it is known that the diagram (p-chart) with the type of product defect still has 13 points exceeding the upper control limit or UCL and there are 12 points exceeding the lower control limit or LCL with a proportion of 0.148. Judging from the results of DPMO calculations and Sigma Levels, an average DPMO of 49619 is obtained, so that if there is a product defect of 49619 out of 1,000,000 opportunities in the Sprouts production process at CV. The Blessing of Aling Bean Sprouts. In the FMEA diagram to find out the factors and RPN values that result in product defects including human factors, machines, materials, methods, and the environment, the results of the FMEA analysis cause the biggest defects, namely yellowing defects with an RPN value of 810.

Temprina Media Grafika is a manufacturing company with printing and packaging services. The products are produced from PT. Temprina Media Grafika are packaging paper for various industrial products. However, the production of PT. Temprina Media Grafika still has a few problems that impact the product flaw. The purpose of this study is to identify the quality of Choco Wafer Roll packaging and offer improvements to improving the Choco Wafer Roll packaged products in PT. Temprina Media Grafika. The study was used are Statistical Quality Control (SQC) and Failure Mode and Effect Analysis (FMEA). Based on the results of research on Statistical Quality Control (SQC), the most dominant defects were color not appropriate (27,2%), after that shiny color not right (23,4%), uneven colors (21,9%), Spots appear on the pack (15,3%), and packaging design cut (12,3%). Based on the results of research on Failure Mode and Effect Analysis (FMEA), it is known that the problem causing disability with the highest RPN value of 168 is the machine factor with the cause of dirty UV polymer containers. Recommendations for improvements that can be made are Eliminating uv polymer containers after uv laminate processes.

PT. Kali Jaya Putra is a manufacturing company that focuses on the production of wood floors. One of the products produced is solid flooring. In a series of production processes, product defects are still found up to 7.5% of total production, defects that often occur such as cracks, pinholes, roughness, and also twists which certainly affect product quality. The research conducted aims to determine the percentage of defective products, the causes of defects and the resulting impacts or effects, and to provide recommendations for improvements to minimize the percentage of defects in solid flooring products at PT Kali Jaya Putra. The method used is Six Sigma and Failure Mode and Effect Analysis (FMEA). The results of this study are that the most dominating defects are crack (53.75%), followed by pinhole defects (36.77%), twist (8.62%), and roughness (0.85%). The causes of defects in products are caused by several factors such as humans, machines, methods, materials, and the environment. Based on FMEA, it is known that the cause of the defect with the highest RPN is 384, namely operator negligence in material sorting. As for recommendations for improvement that can be given, namely conducting training on the grading of raw materials in the hope of minimizing operator errors in sorting raw materials.