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This study aims to analyze product failures and propose improvement actions for cabinet products at CV. Arafah Jaya Purwakarta. Based on production data from November 2024 to April 2025, cabinet products showed the highest defect rate compared to other products, reaching 13%. The most common defects include wood cracks, warped wood, and brittle wood. Failure Mode and Effect Analysis (FMEA) was applied to identify and prioritize potential failures based on the Risk Priority Number (RPN), while Fault Tree Analysis (FTA) was used to systematically determine the root causes of failures. The analysis results indicate that the main causes of defects are related to substandard raw material quality, environmental conditions, and insufficient supervision during the production process. Based on the results of FMEA and FTA, improvement proposals were developed using the 5W+1H approach, focusing on improving raw material selection, controlling wood storage conditions, and enhancing work procedures and production supervision. These improvement efforts are expected to reduce defect rates and improve the overall quality of cabinet products.

This study analyzes failures in the bending machine at PT. XYZ and determines maintenance priorities to reduce downtime and improve production efficiency. The company often faces repeated breakdowns, especially in hydraulic and control components, which negatively impact productivity. To address these issues, the research applies Failure Mode and Effect Analysis (FMEA) and Fault Tree Analysis (FTA). The study employs a descriptive qualitative approach using downtime and repair data from September 2024 to February 2025. FMEA was conducted to identify failure modes, effects, and causes, and to calculate the Risk Priority Number (RPN) as a basis for prioritization. FTA was then applied to trace root causes by mapping logical relationships among contributing factors leading to the top event. Recommendations were formulated with the 5W+1H method to propose preventive maintenance actions. The results indicate that the hydraulic valve is the most critical component, with an RPN value of 504 due to oil contamination. The main causes include damaged filters, improper oil usage, and lack of a cooling system. The hydraulic cylinder seal and back gauge were also found to contribute significantly to machine failures. FTA analysis revealed root causes such as inadequate maintenance procedures, unsuitable materials, and insufficient inspections. The proposed improvements involve regular replacement of oil filters, structured lubrication schedules, installation of oil coolers, and technician training to strengthen compliance with standard procedures. Overall, the integration of FMEA and FTA provides a systematic approach to identify critical components and root causes, enabling PT. XYZ to implement preventive strategies that minimize failures, reduce downtime, and improve bending machine performance sustainably.

The success of a production process is highly dependent on effective quality control. In this study, the focus is directed toward Pc Slab Type A products manufactured by PT. XYZ, a precast concrete company for highways and building structures. The evaluation emphasizes efforts to reduce chipping defects. Improvement priorities were determined using the Failure Mode and Effect Analysis (FMEA) method based on the Risk Priority Number (RPN). Root Cause Analysis (RCA) was applied to identify the underlying problems. The analysis revealed that the dominant factor comes from the human aspect, with the highest RPN value of 294, namely the lack of regular supervision. Additional contributing factors include improper mold opening methods (RPN 216), inconsistent worker performance (RPN 175), inter-division transfers (RPN 125), and delayed maintenance schedules (RPN 120). All causes were elaborated using the 5W+1H approach, covering reasons, locations, timing, implementation, and proposed corrective actions.

PT. YGI, an automotive manufacturing company, uses the Press Injection GB-36 machine in its production process. However, this machine frequently experiences failures, causing high downtime and reduced production efficiency. This study aims to identify the types of failures, determine the most critical components, and propose a maintenance system using the Reliability Centered Maintenance (RCM) approach. The method used is descriptive qualitative, involving FMEA (Failure Mode and Effect Analysis), Logic Tree Analysis (LTA), and maintenance action selection. Data were collected through observations, historical failure documentation, and interviews. The analysis results indicate that components such as the injection nozzle, heating, and clamping are the most critical, contributing over 80% of total failures based on Pareto analysis and the highest RPN values in FMEA. Proposed maintenance actions include Condition Directed and Time Directed approaches. Additionally, the maintenance system is supplemented with standard operating procedures (SOP) and routine inspection schedules to improve machine reliability and reduce production downtime. This study is expected to enhance the efficiency and productivity of the Press Injection GB-36 machine at PT. YGI through the appropriate implementation of RCM.

The continuous operation of airlock machines in wheat milling facilities plays a critical role in the material handling system, especially in the transfer of grain from ships to silo storage. At PT XYZ, the airlock machine has been identified as the equipment with the highest frequency of downtime over a three-month observation period, leading to significant disruptions in production flow and increased corrective maintenance costs. This study aims to analyze the failure modes of the airlock machine using the Failure Mode and Effect Analysis (FMEA) method and to develop preventive maintenance recommendations based on the highest Risk Priority Number (RPN) values. The research adopts a quantitative descriptive approach, involving field observations, interviews with maintenance personnel, historical breakdown analysis, and machine technical documentation review. The FMEA results indicate that the seal, gear, and bearing are the most critical components, with RPN values of 224, 210, and 192, respectively. These components are prioritized for preventive actions such as regular seal replacement, scheduled lubrication, gear inspections, and motor monitoring. Simulation of the proposed maintenance strategy demonstrates a 66.7% reduction in downtime, from 18 hours to 6 hours per month, and a 43.7% reduction in total maintenance costs, from Rp 9,034,500 to Rp 5,087,500 monthly. These results validate the effectiveness of the FMEA method in identifying risk-prone components and optimizing maintenance planning. It is recommended that PT XYZ institutionalize periodic FMEA updates and establish a cross-functional analysis team to continuously monitor and improve equipment reliability.

The Ripple Mill machine is one of the vital components in a Palm Oil Mill (PKS) that functions to separate the palm kernel from its shell. This process is very important because the quality and quantity of the palm kernel produced will directly affect the economic value and production efficiency in the palm oil industry. At PTPN IV Regional II Plantation Unit and Adolina PKS, various technical problems were found that caused a decrease in machine performance, including rotor bars and square bars that experienced wear due to age and improper machine settings. In addition, other damage that often occurs is a broken van belt due to age and excessive tension, feeder motor dysfunction caused by excessive load, and motor overheating that occurs due to age and high workload. To overcome these problems, this study uses the Failure Mode and Effect Analysis (FMEA) method. This method aims to identify various potential failures, assess the severity, frequency of occurrence, and detection capability, so that the Risk Priority Number (RPN) value can be calculated as a basis for repair priorities. The results showed that worn rotor bars and worn square bars had the highest RPN values, each at 280, equivalent to 40.23% of the total identified risks. This indicates that these two components are critical points requiring immediate repair and maintenance attention. Applying FMEA in this context provides tangible benefits, including helping the company formulate a more targeted maintenance strategy, reducing the risk of recurring damage, and minimizing downtime that impacts production. With more systematic maintenance, operational efficiency can be improved while extending the lifespan of the Ripple Mill machine.

The advancement of information technology has driven companies to adopt technology-based systems to enhance operational efficiency while also increasing the complexity of information security risks. This study aims to analyse risk factors associated with information security assets, identify potential threats, assess risks, and provide mitigation recommendations. The OCTAVE method was applied to identify threats, vulnerabilities, and critical information technology assets, while FMEA was used to determine risk mitigation priorities based on the Risk Priority Number (RPN). The mitigation recommendations were developed in accordance with ISO 27001:2022 standards. Data collection was conducted through interviews with XYZ company representatives, identifying 34 information security asset risks, including 6 hardware failure potentials, 6 software failure potentials, 14 data failure potentials, 4 human resource failure potentials, and 4 network failure potentials. The risk categorisation results revealed 5 high-level risks, 6 moderate-level risks, 20 low-level risks, and 3 very low-level risks. The mitigation recommendations include three ISO/IEC 27001:2022 clauses: Human Resource Controls, Physical Controls, and Information Technology Controls.

PT. Dian Swastatika Sentosa generates electricity through a private thermal power plant. This company produces steam and electricity for paper mills. The company hopes to meet its steam and electricity needs in 2023 with a boiler with a load capacity of 180 tons and a maximum capacity of 220 tons. However, from February to July 2023, that goal was not achieved. The most common problems faced by this company are the failure to conduct preventive inspections and timely machine maintenance, as well as the failure to carry out necessary repairs. Delays in machine repairs, which result in inconsistent machine downtime schedules to meet customer demand, leading to damage to boiler equipment, causing abnormal boiler operation and reduced steam production. This research aims to design equipment to withstand operational impacts using failure mode and effects analysis (FMEA) with the Soft Systems Methodology (SSM) and reliability-centered maintenance (RCM) techniques. The RCM method assists in identifying the processes that must be followed to guarantee that a machine or system performs as intended. RCM can also be used to design, choose, and create alternative maintenance methods that are focused on safety, operations, standards, and economics. For the entire problem in the investigation, a dynamic model is necessary. An analytical system is used in this model in order to recognize and duplicate the features of the overall system., as well as to provide repair solutions and address the burden of the problem. This research produces a presentation in the form of problem identification, causal loops, diagrams of machines that frequently experience failures, rich images of the causes and effects of the ball plate crusher liner damage, root cause definitions, and conceptual models for repair and maintenance. business productivity and debating process. 

In carrying out structured maintenance, a method is needed to increase the durability of an aircraft component, one of the methods used is the reliability method. The reliability of aircraft components is very necessary to ensure that each aircraft component is serviceable and runs according to its function in the aircraft system, so to increase the reliability of an aircraft component, the reliability method is very important to do. This study aims to determine the critical life time limit of the asset or system or equipment function and identify the failure mode that occurs in the Gas Turbine Engine component of the Boeing 737-500 aircraft because if this engine fails, it can result in flight delays and if not handled immediately can cause the aircraft to experience Aircraft on Ground (AOG) conditions, because it has the potential to disrupt airworthiness and threaten safety. This study uses exploratory research which aims to simplify problems to make them easier to solve. This study uses the Pareto diagram method to determine the highest type of failure in components, then analyzes it using the failure mode effect analysis (FMEA) method. Based on FMECA and FTA analysis, there are 3 failure modes, the failure modes include mechanical system (Bleed Valve), pneumatic system (Butterfly Shaft), electrical system (actuator). The failure was due to the occurrence of the top event part consumable, namely the bleed valve part with an RPN value of 192, followed by the butterfly shaft part with an RPN value of 75 and the Actuator part with an RPN value of 72. The pneumatic system and electrical system categories are prioritized to carry out preventive maintenance, which means it is a solution from industry players in an effort to maximize maintenance of the turbofan engine system accompanied by technical or economic analysis to ensure a system in extending the service life of parts in the aircraft system.

This research aims to analyze the risk of work accidents at PT Sermani Steel Corporation using the Failure Mode Effect Analysis (FMEA) method. This method is applied to identify potential hazards in the production process of zinc coated steel, such as hollow, C channel, and battens. Data were collected through questionnaires, observations, and interviews, then processed to calculate the Risk Priority Number (RPN). The results showed that the highest risk was found in zinc machine production activities, with an RPN value of 321.6, mainly related to the risk of being cut by products or product debris. Based on Pareto and Fishbone Diagram analysis, the main causes of accidents are human, machine, method, and environmental factors. The conclusions emphasize the importance of OHS training, installation of signs and indicator lights on machines, and close supervision to minimize the risk of accidents. The recommendations provided are expected to reduce work accidents by 38% of the total accidents that occur in the production area.

Quality risk management is one of the important things in quality control in a pharmaceutical industry. One of the risky activities in the pharmaceutical industry is in storage and distribution. Every activity carried out in the inventory warehouse can potentially cause risks that affect quality including the flow of the storage and distribution process of goods. Based on this, a study was conducted in the form of a risk assessment on the flow of the storage and distribution process of release goods in the inventory warehouse of a pharmaceutical industry in Bandung which aims to determine the level of risk that has the potential for failure. The FMEA (Failure Modes and Effects Analysis) method is a method that can be used to assess the risks that can occur in the flow of the storage and delivery process of goods in the warehouse. This risk assessment is carried out with the stages of risk identification, risk analysis, and risk evaluation using categorization based on the Risk Priority Number (RPN). In this study, 15 risks were obtained with details of 1 low category risk, 7 medium category risks, 6 high category risks, and 1 very high category risk. Therefore, the pharmaceutical industry can immediately determine mitigation steps and take control measures against risks in the high and very high categories to reduce the risk of failure with the hope that the quality, safety and efficacy of the product can be maintained properly

Developments in the world of manufacturing industry are increasing, very tight industrial competition is encouraging industry to increase production effectiveness. PT. PAN Brothers is a manufacturing industry located in Boyolali, Central Java. PT. PAN Brothers produces clothing types such as jackets, coats, ski jackets, down jackets, tracksuits, travel pants and so on. During the production process, sewing machines have problems, namely machine damage. This research aims to analyze the effectiveness of sewing machine performance using the Overall Equipment Effectiveness (OEE) method and provide suggestions for improving the results of the Failure Mode and Effect Analysis (FMEA) method. The measurement uses the OEE method with three main components, namely availability rate, performance rate and quality rate to identify types of losses based on the six big losses. The average OEE value of 60% is still below world class standards with factors influencing the low OEE value. namely the performance rate, while the losses that affect the effectiveness value of the performance rate are Idling and minor stoppages losses with a value of 42%. By carrying out root cause analysis using a fishbone diagram, the root causes of low performance values ​​influenced by Idling and minor stoppage losses are known, namely machine factors, human factors, methods, materials and the environment. After identifying the problem and measuring the Risk Priority Number (RPN), suggestions for improvement were obtained including providing training to operators, to implement a preventive maintenance system, adding employees in the line balancing section and adding equipment to support machine repair facilities.      

PG Madukismo is a sugar factory that was established in 1955 and is the only sugar factory in the province of the Special Region of Yogyakarta. This factory is located in Padokan Village, Tirtonirmolo Village, Kasihan District, Bantul Regency, Special Region of Yogyakarta. PT Madubaru, a company engaged in sugar cane processing, is a sugar and spirits factory located in the Yogyakarta area. Companies that produce cane sugar with SHS IA quality. Product defects are often found, resulting in a decrease in quality, therefore it is necessary to carry out quality control. This study uses the Failure Mode and Effect Analysis (FMEA) method to identify failure modes, Logic Tree Analysis (LTA) to determine the consequences of failure arising from failure modes and determine effective preventive maintenance policies for each machine. For the production quality control section, the Statistical Processing Control (SPC) method is used to analyze product defects to determine whether product defects are still within controllable limits or not. While the Failure Mode and Effect Analysis (FMEA) method is used to determine the failure mode in sugar production. For the quality control section on raw materials using the Economic Order Quantity (EOQ), Re-Order Point (ROP), Safety Stock (SS), and Total Inventory Cost (TIC) methods. The conclusion of this study is regarding the results of the analysis and calculations carried out with several settlement methods and there are several causes of production defects from 5 factors, such as: human factors, work methods, environment, raw materials and machines used. And provide solutions to companies in order to reduce defects by controlling product quality.    

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. Diamondfit Garment Indonesia is a company operating in the apparel industry, especially intimates and swimware. One of the products is the Intimates fused bra. In the production process, many defects are still found. This research aims to propose quality improvements using the six sigma method starting from the define, measure, analyze, improve and control stages. At the define stage, the production process is identified using the SIPOC diagram and identification of the type of defect. At the Measure stage, the calculation stage is carried out: fusing delamination DPMO value 366405.6 with a sigma value 1.84, Wavy At Neckline & Armhole DPMO value 65274.15 with a sigma value 3.01, Molding Yellowish DPMO value 350739.8 with a sigma value 1, 88, Dirty Glue has a DPMO value of 26109.66 with a sigma value of 3.44, and Heat Seal Not Sticking has a DPMO value of 191470.8 with a sigma value of 2.37. As a result of the analysis, it was found that factors causing defects occurred using FMEA tools and fishbone diagrams, namely machine, manpower, material and method factors. In the improvement stage, improvements are made to the factors causing defects and in the control stage, supervision is carried out over the proposed improvements that have been made by creating SOPs.

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.                                                                                                      

The purpose of this study is to analyze the safety operational process in fiberglass shipbuilding, identify the types of risk causes that hinder the construction of fiberglass boats and propose recommended actions needed to overcome the risks in CV ERA FIBERBOAT by using theoretical research methods. Identification of risks in the process of building new ships, namely employees, materials, work equipment, payment of construction costs, working drawings have revisions. Determining the risk rating of the new ship building process: very high; inappropriate equipment, height; late payment / paying, medium; working drawings have revisions, low; materials arrive late, very low; employees procrastinate. Mitigating risks in the process of building new ships: employees delay work with mitigation, namely the director of the company provides the opportunity for employees to rest so that employees do not get sick, materials arriving late are mitigated by means of shipyard companies providing an easy-to-find address point so that the sender of materials does not having difficulty finding the address of the shipyard, working drawings have revisions that can be mitigated by means the company must always make an existence to the customer in every work process so that there is no miscommunication