Failure Risk Analysis in the Plastic Yarn Production Process Using the FMEA Method and Kaizen Approach

Ananda Bayu Dewantara, Said Salim Dahda, Said Salim Dahda

Abstract


The manufacturing industry is a key pillar in global economic growth, yet the risk of failure remains a crucial challenge. PT XYZ, a plastic yarn manufacturer in Gresik, faces similar challenges despite achieving success. The production process is not yet optimal, with a defect rate exceeding the standard limit. This research utilizes the FMEA and Kaizen approaches to identify priority failure modes and propose improvements. Analysis indicates that yarn spot defects are the top priority for correction, attributed to insufficient pump pressure. Proposed improvements based on the Risk Priority Number include installing pressure control devices, implementing preventive maintenance, and providing support facilities for operators. Therefore, these improvements are expected to enhance the efficiency and the quality of the plastic yarn production process at PT XYZ Gresik.

 

Keywords: Diagram Pareto, Diagram Fish Bone, FMEA, Kaizen

 


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DOI: http://dx.doi.org/10.24014/sitekin.v21i2.29601

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