PROCESS QUALITY IMPROVEMENT USING FAILURE MODE AND EFFECT ANALYSIS (FMEA) IN CALLIPER PISTON PRODUCTION

Abstract

PT. PF is one of the subsidiaries of PT. PC that focuses on metal forming, especially the cold forging method and one of their products is Piston Calliper. PT. PF often finds defective products produced during the production of the piston calliper, with the highest defect products produced as many as 1,852 units of defect products in June 2021 thus affecting the income generated by the company. To reduce this defect product, improvements are made using the FMEA method, in which there are 7 stages carried out, namely, review the process using process flow chart, identify the most common type of defect, identify the potential effects of each failure, determination of severity, occurrence, detection, and RPN values, identifying the cause of defect, develop an action plan and its implementation, and calculate the resulting RPN. After improvement was carried out the defect products produced by the company decreased by 48% for the types of defects that could not be repaired, and 33% for the types of defects that could be repaired compared to the same month in the previous year, and the total net profit obtained by the company changed from Rp. 20,525,440,186 to Rp. 20,619,987,885.