Implementation of Tree Diagram Method, Failure Mode Effect Analysis (FMEA) and 5W 1H to Reduce Corky Defective Products in PT. XYZ

Mohamad Solihudin; Wakhid Nurhidayat; Suwandi Suwandi; Candra Setia Bakti; Rachmat Rachmat; Agus Hari Hadi; Sapta Nugroho

doi:10.22441/ijiem.v4i1.17237

Authors

Mohamad Solihudin Universitas Yuppentek Indonesia, Indonesia
Wakhid Nurhidayat Universitas Yuppentek Indonesia, Indonesia
Suwandi Suwandi Universitas Yuppentek Indonesia, Indonesia
Candra Setia Bakti Universitas Yuppentek Indonesia, Indonesia
Rachmat Rachmat Universitas Yuppentek Indonesia, Indonesia
Agus Hari Hadi Universitas Yuppentek Indonesia, Indonesia
Sapta Nugroho Universitas Yuppentek Indonesia, Indonesia

DOI:

https://doi.org/10.22441/ijiem.v4i1.17237

Keywords:

Corky defect, Tree diagram, FMEA, Potential failures, 5W 1H

Abstract

PT XYZ is a company that manufactures of tire fabrics in the Tangerang. Global competition force the company continues to strive to reduce process costs, one of which is by reducing the highest percentage of defects, namely corky defects, corky defects reach 39.7% of total defects. The tree diagram and FMEA methods, selected for the analysis of potential failures that cause corky defects are found namely: Threads are not clamped when changing pots, joints are not pulled at the beginning of running, roll regulator worn is used for the process, dirty of roll regulator is used for the process, wrong setting inner brake. The 5W 1H method results from corrective actions, namely: Refreshing programs for twisting production operators, checking periodically the roll regulator used by the process is still good, making schedules, and reporting on the implementation of cleaning roll regulators and evaluating by production leaders. From the corrective actions taken, it succeeded in reducing the percentage of corky defects in the twisting plant 2 process, down from 39.7% to 14.9% in semester 2 of 2021.

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