FMEA-BASED QUALITY IMPROVEMENT IN WASHBASIN MANUFACTURING PROCESS
DOI:
https://doi.org/10.59134/jimat.v4i1.819Keywords:
Defect Analysis, Failure Mode and Effect Analysis, Manufacturing Process, Quality Improvement, Washbasin ProductionAbstract
This study analyzed quality control problems in the washbasin manufacturing process at a sanitary product manufacturing company. The study aimed to identify dominant defect types, determine potential failure causes, and propose improvement recommendations to reduce product defects. A quality improvement approach was applied using Pareto analysis, Failure Mode and Effect Analysis (FMEA), fishbone analysis, and the 5W+1H method. Production data from September to November 2025 were analyzed to identify defect distribution and prioritize improvement areas. The results showed that the production process generated 168 defective products from 2,181 produced units, resulting in a defect rate of 12.01%, which exceeded the company target of 6%. The dominant defects identified were cracks, body dust contamination, and body deformation. The FMEA analysis determined the highest-risk failure modes based on the Risk Priority Number values, which were associated with material handling, process control, and operator-related factors. Improvement recommendations were developed through process standardization, operator training, material control improvement, and enhanced inspection procedures. The proposed actions provided a structured approach to improve product quality and reduce potential failures in the washbasin manufacturing process
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