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All Journal Jurnal Rekayasa Sistem Industri
Rianto, Tiffany R
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Industrial & Manufacturing Engineering

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Applying ADDIE Methodology and Vision Inspection to Reduce Missing Parts Defects in Toy Manufacturing Maukar, Anastasia Lidya; Rianto, Tiffany R
Jurnal Rekayasa Sistem Industri Vol. 15 No. 1 (2026): Jurnal Rekayasa Sistem Industri
Publisher : Universitas Katolik Parahyangan

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.26593/jrsi.v15i1.9668.76-92

Abstract

This research addresses missing parts defects in Advent Calendar toy production, a critical quality issue causing customer dissatisfaction and financial losses. The ADDIE methodology was applied as a systematic framework to analyze root causes, redesign ergonomic workstations with improved human-machine interactions, develop a vision inspection system, implement operator training, and evaluate outcomes. Results demonstrated significant improvements: defect reduction of 92% (from 53 to 4 cases), operator cycle time reduction of 75% (from 70.68 to 14.85 seconds), improved ergonomic conditions (RULA score decreased from 5 to 4), and labor cost savings of 75% (approximately IDR 1.2 billion annually). This study demonstrates that ADDIE provides a systematic, measurable approach for integrating human factors and technology to enhance inspection performance and support continuous improvement in manufacturing.
Co-Authors Anastasia Lidya Maukar