Towards zero-defect manufacturing: A proactive quality risk assessment of welding imperfections in wind tower production

Yusraini Muharni (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Evi Febianti (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Muhammad Adha Ilhami (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Ade Irman Saeful Muttaqien (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Lely Herlina (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Muhammad Rafi Hasyim (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Anting Wulandari (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Kulsum Kulsum (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Hartono Hartono (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)
Maria Ulfah (Department of Industrial Engineering, Universitas Sultan Ageng Tirtayasa)

Journal Industrial Servicess
Vol 12, No 1 (2026): April 2026

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.