<![CDATA[PT Dellifood Sentosa Corpindo, a cup noodle manufacturing company, faces a high level of packaging reject ini its packing process. During the period of October 2025 – January 2026, the average reject rate reached 6,17%, exceeding the company standard of 4,46%. This condition has resulted in decreased productio efficiency, increased material waste, and a growing amount of packaging waste, which is not aligned with the principles of green manufacturing. This study aims to identify the root causes of packaging rejects, determine the priority of failure risks, and propose improvement actions to reduce the reject rate. The methods employed in this study were Root Cause Analysis (RCA) to identify the main cause of defect using a fishbone diagram and Failure Mode and Effect Analysis (FMEA) to prioritize risk based on the Risk Priority Number (RPN). The research data were collected through observations of the packing process during the period of February – May 2026. Based on the data analysis, the primary cause of the packaging defects was found in the end/long sealer process. Futhermore, the highest RPN value was identified in the issue of poor-quality thermocouple cables, with the machine factor being the main cause, resulting in a RPN value 280. Corrective actions were implemented though the modification of the thermocouple cable using a ring lug and application of green manufacturing principles through waste identification, implementation of succesfully reduced from 3,79% to 3,21%. The findins indicated that the implenetation of Root Cause Analysis (RCA), Failure Mode anda Effect Analysis (FMEA), and Green Manufacturing is effective in reducing packaging rejects, improving material utilization efficiency, and supporting sustainable production process.]]>
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