<![CDATA[This study was conducted in the Incoming Inspection department of PT XYZ, a garment manufacturing company, and was motivated by the increasing percentage of nonconforming 18L button materials, which rose from 1.30% in 2023 to 2.25% in 2025. This condition highlights the importance of identifying and controlling risks in the material inspection process. The study aimed to identify potential risks, determine risk priorities, analyze their root causes, and propose improvement measures for the 18L button material inspection process. A descriptive-evaluative case study design with qualitative and semi-quantitative approaches was employed using the Failure Mode and Effects Analysis (FMEA) and Root Cause Analysis (RCA) methods. Data were collected through direct observation, company documentation, and FMEA assessments conducted by three purposively selected respondents. Risk assessment was performed using the Severity, Occurrence, and Detection parameters, followed by the calculation of the Risk Priority Number (RPN). The results identified ten potential process risks, with three priority risks: undetected hairline cracks or broken buttons (RPN = 360), unidentified color differences (RPN = 336), and undetected blocked buttonholes (RPN = 210). The RCA results revealed that these risks were primarily associated with inspection procedures, visual reference standards, lighting conditions, and inspection aids. Based on these findings, several improvement proposals were developed, including the standardization of inspection procedures, refinement of work instructions, provision of inspection aids, and the development of a poka-yoke concept to improve the consistency of the Incoming Inspection proces.]]>
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