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All Journal PROZIMA (Productivity, Optimization and Manufacturing System Engineering) Journal of Industrial Engineering Innovation
Luqman Hakim, Achmad
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Industrial & Manufacturing Engineering

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Evaluation of Quality Failures in the Production Process Using the Seven Tools and Failure Mode and Effect Analysis (FMEA): Evaluasi Kegagalan Kualitas Proses Produksi Menggunakan Metode Seventools dan Failure Mode and Effect Analysis (FMEA) Luqman Hakim, Achmad; Widiasih, Wiwin
PROZIMA (Productivity, Optimization and Manufacturing System Engineering) Vol. 9 No. 2 (2025): December
Publisher : Universitas Muhammadiyah Sidoarjo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21070/prozima.v9i2.1761

Abstract

CV. Simetri Utama, a manufacturer of frozen shrimp molds, has two dominant types of defects: imperfect codes and uneven shapes. Based on the research findings, the product defect rate exceeds the company standard of 3%. This study aims to identify the types of defects, analyze the contributing factors and impacts of failures, and propose improvement recommendations to minimize the risks of product defects. The methods used are the Seven Tools and Failure Mode and Effect Analysis (FMEA). The Seven Tools are applied to analyze and resolve issues related to product quality. The results show that uneven shape defects account for 54.55%, making them the most dominant, followed by imperfect code defects at 45.45%. Failure Mode and Effect Analysis (FMEA) is utilized to determine the priority level of risks through the assessment of Severity, Occurrence, and Detection. The main contributing factors include improper tool and zero-point settings, incorrect tool selection, suboptimal parameters, as well as environmental and machine conditions. Based on the Risk Priority Number (RPN) generated through the FMEA approach, six failure types are prioritized for evaluation, namely finishing, roughing, tool offset adjustment, semi-finishing, zero-point setting, with tool offset adjustment being the top priority for improvement. The application of the Seven Tools and FMEA methods is expected to reduce the risks of identified potential failures, thereby lowering the defect rate and continuously improving product quality
Penerapan Metode Poka-Yoke dan Kanban untuk Meningkatkan Efisiensi Produksi Sepatu di PT. XYZ Fiky Two Nando; Permadi, Rama; Luqman Hakim, Achmad; Tri Arnanda, Halif; Ardiansah, Arki
Journal of Industrial Engineering Innovation Vol. 4 No. 01 (2026): April 2026
Publisher : Insight Publisher, Makassar, Indonesia

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Abstract

Penelitian ini bertujuan mengeksplorasi penerapan metode Poka-Yoke dan Kanban pada perusahaan sepatu hipotetis PT. XYZ menggunakan data dummy sebagai pendekatan simulatif. Data yang digunakan meliputi produksi harian sebesar 1.000 pasang sepatu, tingkat cacat awal 5%, dan work in process (WIP) sebanyak 1.000 pasang. Hasil simulasi menunjukkan bahwa implementasi Poka-Yoke mampu menurunkan tingkat cacat secara signifikan hingga 0,1% serta menghasilkan penghematan biaya sebesar Rp 73.500.000 per bulan. Sementara itu, penerapan Kanban berhasil mengurangi WIP sebesar 70% dengan penghematan mencapai Rp 210.000.000 per bulan. Analisis finansial menunjukkan nilai return on investment (ROI) sebesar 782% untuk Poka-Yoke dan 4.940% untuk Kanban. Integrasi kedua metode tersebut juga terbukti meningkatkan throughput produksi sebesar 18,75%. Meskipun berbasis data simulasi, penelitian ini memberikan gambaran kuat bahwa pendekatan lean manufacturing berpotensi meningkatkan efisiensi operasional, kualitas produk, dan kinerja finansial secara signifikan dalam industri manufaktur sepatu
Co-Authors Ardiansah, Arki Fiky Two Nando Permadi, Rama Tri Arnanda, Halif Wiwin Widiasih