<![CDATA[PT Banyu Reverse Osmosis is a bottled water (AMDK) company under the BAROS brand, producing 19-liter, 240 ml cups, 330 ml bottles, and 600 ml bottles. During June 2025-May 2026, the 19-liter recorded an average defect rate of 10.98% per month, dominated by thin seal defects (59.17%), damaged caps (35.50%), and leaking gallons (5.33%). This study aims to identify the causes of product defects, determine risk priorities using Failure Mode and Effect Analysis (FMEA), find rRot causes through Rot Cause Analysis (RCA) with the 5 Whys technique, and propose improvements. This study used a descriptive quantitative approach with check sheets, Pareto diagrams, Fishbone diagrams (4M+1E), FMEA, and RCA. Production and reject data were processed through defect-type identification, cause mapping, and risk assessment based on Severity, Occurrence, and Detection to obtain Risk Priority Number (RPN) values, followed by rRot-cause tracing using 5 Whys on the causes with the highest RPN. The results show the highest RPN was 210, caused by improper headlayer machine settings, followed by unstable headlayer temperature/pressure (RPN=180). RCA revealed three rRot causes: absence of standard SOPs and checklists, no scheduled preventive maintenance, and excessive operator workload. Proposed improvements include SOPs and checklists, monthly preventive maintenance, improved human resource management, and strengthened quality control with weekly control charts, targeting a reduction of thin seal defects from 10.89% to below 5% within six months.]]>
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