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All Journal Journal of Creative Student Research
Alan Fadlianto
Universitas Pelita Bangsa
Humanities Decision Sciences, Operations Research & Management Education Languange, Linguistic, Communication & Media Social Sciences Transportation

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Pengendalian Kualitas untuk Menurunkan Defect Produk Pipe Brake Menggunakan Metode Seven Tools dan FMEA dengan Pendekatan Kaizen di PT. XYZ Alan Fadlianto; Hana Silvia Dwi Putri; Fibi Eko Putra
Journal of Creative Student Research Vol. 4 No. 2 (2026): April : Journal of Creative Student Research
Publisher : Lembaga Pengembangan Kinerja Dosen

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.55606/jcsr-politama.v4i2.6467

Abstract

This study aims to reduce the defect rate of pipe brake products at PT. XYZ by integrating Seven Tools, Failure Mode and Effect Analysis (FMEA), and Kaizen methods. Based on identification using check sheets and Pareto diagrams, five main types of defects were found, where "uninstalled clips" were the most dominant, contributing 48%, followed by leaking pipes (21%) and dented pipes (15%). FMEA analysis revealed that the failure cause with the highest risk, indicated by the highest Risk Priority Number (RPN) score of 378, was the absence of an automatic control system in the clip installation process. Other contributing factors included inadequate brazing machine maintenance, lack of material handling standards, and weak quality control from suppliers. Through the Kaizen approach using 5 Whys and 5W+1H analysis, this research formulated technical improvement proposals such as the implementation of poka-yoke (error-proofing) systems, revision of Standard Operating Procedures (SOP), routine maintenance schedules, and visual control-based inspection systems. The implementation of these strategies is intended to reduce the initial defect ratio of 2.18% to a minimum level to achieve sustainable quality improvement in the production line.
Co-Authors Fibi Eko Putra Hana Silvia Dwi Putri