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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.

The construction sector is an industry with a high level of work accident risk due to its dynamic and complex work characteristics. This study aims to examine the application of the Occupational Health and Safety (OHS) System and evaluate its effectiveness in mitigating risks at the Health Facility Building Construction Project (Project X) in Fakfak Regency. The research method used is a descriptive-analytical quantitative approach with purposive sampling of 25 respondents, including executors, supervisors, and field workers. Risk analysis was conducted using the Failure Modes and Effects Analysis (FMEA) method by measuring Severity, Occurrence, and Detection parameters to produce a Risk Priority Number (RPN). The results show that RPN values range from 52.35 to 452.30. The highest risk was found in the variable of limited safety signage in hazardous locations (RPN 452.30), which falls into the very high category. Additionally, 10 high-risk variables and 9 medium-risk variables were identified, dominated by technical, operational, and management factors, such as the use of heavy equipment by uncertified operators and weak implementation of Standard Operating Procedures (SOP) and OHS audits. This study concludes that the application of OHS in Project X is still reactive and requires strengthening risk-based safety management systems as well as improving workforce competence to achieve zero accident conditions.

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 spice industry faces significant challenges in maintaining product weight consistency as part of quality assurance and compliance with production standards. A case at PT X revealed that a newly installed filling machine produced deviations from the target weight of 50 grams, with hypothesis testing showing that out of 30 samples, 17 samples fell outside the  confidence interval. To mitigate this issue, this study proposes the development of a real-time data-driven Decision Support sistem (DSS) combined with statistical approaches. The methodology includes two-tailed hypothesis testing to detect weight deviations and Failure Mode and Effects Analysis (FMEA) to identify dominant failure causes based on high Risk Priority Numbers (RPN), such as delayed machine calibration, operator error, and worn-out machine components. These findings serve as the foundation for designing the DSS architecture, which consists of sensor input modules, statistical data processing, risk mapping, and an automated corrective recommendation engine. The sistem is designed to enable early detection of deviations, accelerate response time to quality issues, and support data-driven decision-making on the production floor. The study concludes that a structured implementation of DSS can be an effective strategy to improve product weight consistency and enhance operational efficiency in spice manufacturing.  

The use of information technology (IT) in the government sector requires structured risk management to ensure the continuity of public services. The Department of Communication and Information Technology (Dinkominfo), as a digital service provider, faces various potential risks such as network disruptions, hardware failures, and cyberattacks that could interfere with daily operations. This study employs the Failure Mode and Effect Analysis (FMEA) method to identify, analyze, and formulate strategies to mitigate existing IT risks. Through the FMEA approach, each potential failure is evaluated based on its severity, occurrence, and detection capability, which are then used to calculate a Risk Priority Number (RPN). The analysis reveals that the highest RPN values are associated with information system errors, hardware failures, and network overloads. As mitigation measures, the study recommends conducting regular system audits, upgrading network capacity, and performing preventive maintenance on devices. This approach demonstrates that FMEA is an effective method for managing IT risks within government institutions.

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.

UD. Sarigut Bakery is known as one of several industries that focus on processing bread specifically in the Banda Aceh City area that seeks to produce with a variety of bread. The purpose of this study is to carry out efforts to identify, measure efforts, and analyzing efforts to the phase known to be the cause of the decline in quality of the production process of meses bread through a series of stages of the DMAIC SIX SIGMA methodology. It is known that the main problem is the discovery of disability with a total of 4,096 of the total production of the production of 21896 with a period of 3 months specifically in the dominant disability of Meses bread in the percentage of 81.29%. With the dominant of the disability itself the disability that comes in damaged bread with a percentage of 36.49% present from all of the total disability of related meses bread. After the assessment effort, the DPMO value was obtained by 26723.74 so that there were several levels of Sigma 3, which means it was still far from the world industry level which reached 6σ (3.4 DPMO). Efforts to analyze the data carried out by applying the Fishbone and FMEA (Failure Mode and Effect Analysis) diagrams are known to be related to the cause of the presence of disability from damaged bread with 3 modes of failure in potential, namely bread that is not filled with chocolate with a value of 20, the upper bread with a value of RPN of 80 and failure mode on broken bread with the highest RPN value of 90.

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.

This study aims to analyze the failure risks of UV digital printing machines used at PT XYZ using the Failure Mode and Effects Analysis (FMEA) method. In the digital printing industry, the continuity of machine operations heavily depends on effective maintenance to prevent downtime that could disrupt the production process. The FMEA method is employed to identify potential failure modes and evaluate the severity, occurrence, and detection of each failure. This research adopts a quantitative approach, with data collected through observations, interviews, and historical documentation. The analysis reveals that the printhead, cooling system, and UV lamp are the components with the highest Risk Priority Numbers (RPN), at 504, 441, and 288 respectively. Based on these findings, it is recommended that preventive and predictive maintenance strategies be enhanced to avoid recurring failures.

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 Primayudha Mandirijaya adalah perusahan manufaktur pemintal benang yang pada setiap kegiatan produksinya mesin sangat berperan penting. Salah satu mesin produksi pengolah material rayon menjadi sliver yaitu mesin carding. Penelitian ini membahas mengenai perawatan dan perbaikan unit mesin carding di spinning 3 PT Primayudha Mandirijaya yang menyebabkan penurunan kinerja produktivitas pada tahap selanjutnya yaitu drawing menjadi tidak optimum. Tujuan dari penelitian ini untuk mengetahui komponen mesin carding yang memiliki nilai RPN (Risk Priority Number) paling tinggi dan melakukan evaluasi pada komponen tersebut. Pada penelitian ini metode yang digunakan adalah metode FMEA (Failure Mode and Effect Analysis). Kegagalan dari setiap komponen akan dilakukan perankingan dengan menghitung nilai RPN untuk menentukan komponen prioritas perbaikan. Berdasarkan hasil analisis menggunakan metode FMEA diperoleh nilai rata-rata skala Risk Priority Number (RPN) yaitu 161,6, dan komponen yang menjadi pritoritas utama adalah Mounting Doffer sebesar 360, kemudian Stationary Flat dengan RPN sebesar 280, delivery roll dengan RPN sebesar 175, dan Belt Cylinder dengan RPN sebesar 168. Faktor penyebab kegagalan setiap komponen adalah lifetime tercapai, kelalaian manusia, dan perbedaan antara komponen import dan lokal.

PT Yogya Presisi Tehnikatama Industri adalah perusahaan bidang manufaktur, pembuat cetakan injeksi plastik. Permasalahan yang dihadapi perusahaan yaitu terdapat produk cacat dalam proses produksinya sehingga diperlukan upaya perbaikan kualitas. Penelitian ini bertujuan untuk mengidentifikasi tingkat kerusakan yang signifikan dan faktor-faktor penyebabnya. Metode yang digunakan metode Six Sigma dengan tahapan DMAIC ( Define, Measure, Analyze, Improve , dan Control ) dan Failure Mode and Effect Analysis . Hasil pembahasan tahap mendefinisikan diketahui produk yang dipilih Container GS serta pendefinisian spesifikasi produk CTQ, alur penggunaan diagram SIPOC. tahap pengukuran diketahui terdapat 6 jenis CTQ, persentase cacat tertinggi yaitu jenis cacat dimensi variabel, dari perhitungan nilai DPMO didapat sebesar 21.157 dan 3.55 sebagai nilai sigma . Dari peta kendali menghasilkan proses produksi yang belum mencapai kestabilan, tahap analisa pada diagram pareto dimensi variabel cacat sebesar 24% dan cacat awal sebesar 19%. Berdasarkan diagram fishbone penyebab cacat oleh faktor man, machine, method, material . Tahap perbaikan dari analisis hasil FMEA mendapatkan nilai RPN tertinggi dengan nilai 720 faktor manusia karena kurang disiplin dalam menjaga kebersihan area penyimpanan material dan peralatan kerja. Tahap kontrol melakukan perbaikan dari hasil FMEA yaitu melakukan pembersihan area penyimpanan secara berkala.

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

Cross-contamination occurs due to other previously produced products, other rooms or areas producing different products, and particles from machinery or equipment. Quality risk management can be a preventive measure in reducing the potential for cross-contamination that occurs in the pharmaceutical industry. One part of quality risk management is risk assessment. One of the most common and effective methods is the Failure Mode and Effect Analysis (FMEA) method. This risk assessment is carried out using the stages of risk identification, risk analysis, and risk evaluation using categorization based on the Risk Priority Number (RPN). Based on the risk assessment using the FMEA method regarding cross-contamination in the Packaging area in the "XYZ" pharmaceutical industry, it can be concluded that the results of observations and interviews with operators and Packaging Supervisors identified 19 risks which were categorized as low, medium, high, and very high. Based on the results of the risk assessment obtained, the risk of cross-contamination that needs to be controlled is those with an RPN value of 30 ≤ RPN ≤ 60 (medium); 75 ≤ RPN ≤ 100 (high); RPN ≥ 150 (very high). Therefore, the "XYZ" pharmaceutical industry needs to determine and implement risk control measures. By adequately controlling the potential risk of cross-contamination, it will ensure the safety and quality of the products produced.

PT Swadaya Graha is a company that works in the field of construction, fabrication and steel manufacturing. One of the machines used in carrying out its operational activities is the Baoji 1660A lathe. The lathe often fails during the production process. This study aims to determine critical components, critical component reliability values, maintenance scheduling intervals and maintenance cost estimates of the Baoji 1660A lathe using the Reliability Centered Maintenance (RCM) method. The results of this study show that the electrical system with an RPN value of 240, v-belt with an RPN value of 168, and gearbox with an RPN value of 60 as critical components. The reliability value of the electrical system approaches 0.5 at a time interval of 640 hours or 80 working days, the reliability value of the v-belt approaches 0.5 at a time interval of 208 hours or 26 working days, and the reliability value of the gearbox approaches 0.5 at a time interval of 384 hours or 48 working days. From the scheduling interval, the estimated total maintenance cost in 2025 is IDR 7,019,092, in 2026 is IDR 3,615,386, in 2027 is IDR 4,187,484, in 2028 is IDR 4,276,752, and in 2029 is IDR 3,615,386.

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.