USULAN PERBAIKAN PROSES PRODUKSI PINTU PADA PT. XYZ MENGGUNAKAN METODE PROCESS FAILURE MODE AND EFFECT ANALYSIS (PFMEA) DAN CONTINUOUS IMPROVEMENT

Abstract

The importance of quality in a product's growth in order to stabilize the market. To improve the quality of a product, a company must prioritize product development and minimize waste. PT. XYZ is a company that manufactures door made of aluminum, polyvinyl chloride (PVC), and wood. There are several defects that occur throughout the manufacturing process, particularly during the aluminum and PVC manufacturing processes. The purpose of this study is to improve product quality throughout the manufacturing process, identify potential causes of defect, and provide solutions for preventing defect during the manufacturing process. There are two types of defect on each production process. aluminum door manufacturing process occurs dent and imperfect perforation, besides PVC door manufacturing process occurs cracked doorway and rough cutting. The analysis was conducted utilizing pareto diagram, fishbone diagram, and the Process Failure Mode and Effect Analysis (PFMEA) method. To provide a solution, this study employs 5 Why analyisis with using 5 times “why” repetition iteration technique to seek root of the problem from the occurred potential failure. Result of the research refer that RPN score from code F decrease 528 point after improvement simulation to be 32 point, code D decrease 236 point after improvement simulation to be 84 point, code B2 decrease 404 point after improvement simulation to be 16 point and code decrease 302 point after improvement simulation to be 18 point.