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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.

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.

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

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.      

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.