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Hartono Hartono
Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa
Computer Science & IT Control & Systems Engineering Decision Sciences, Operations Research & Management Economics, Econometrics & Finance Engineering Industrial & Manufacturing Engineering Mechanical Engineering Transportation

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Towards zero-defect manufacturing: A proactive quality risk assessment of welding imperfections in wind tower production Yusraini Muharni; Evi Febianti; Muhammad Adha Ilhami; Ade Irman Saeful Muttaqien; Lely Herlina; Muhammad Rafi Hasyim; Anting Wulandari; Kulsum Kulsum; Hartono Hartono; Maria Ulfah
Journal Industrial Servicess Vol 12, No 1 (2026): April 2026
Publisher : Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.62870/jiss.v12i1.40342

Abstract

Wind tower manufacturing demands exceptionally high-quality standards due to its critical role in renewable energy infrastructure. However, defect occurrences during the production process remain a persistent challenge that can compromise structural integrity, increase rework costs, and delay project delivery. This study aims to identify, analyse, and evaluate the risk of defects in the wind tower production process by using an integrated approach of 5 Whys and Failure Mode and Effects Analysis (FMEA). The 5 Whys methodology was employed to trace the root causes of recurring defects, while FMEA was utilized to assess failure modes based on severity, occurrence, and detectability values, resulting in a Risk Priority Number (RPN) for each identified failure. The 5 Whys analysis revealed that the root of the problem lies in the absence of a procedure for verifying work positions before welding. The improvements focused on the design the standard operating procedure, increasing operator competency, controlling process parameters, and validation through trials and inspections to support a decrease in the level of defects and improve product quality.
Co-Authors Ade Irman Saeful Muttaqien Anting Wulandari Evi Febianti Kulsum Kulsum Lely Herlina Maria Ulfah Muhammad Adha Ilhami Muhammad Rafi Hasyim Yusraini Muharni