Failure Mode and Effects Analysis Method Implementation to Reduce Losses in Pile Products at PT XYZ

Penerapan Metode Failure Mode and Effects Analysis Untuk Mengurangi Kecacatan Pada Produk Tiang Pancang Di PT XYZ

Abstract

The precast concrete industry plays a crucial role in supporting infrastructure development, particularly in the provision of structural elements such as piles, which require high quality and reliability. However, the complexity of the pile production process can potentially lead to various product defects that can reduce quality and increase production costs. This study aims to analyze pile product defects at PT XYZ and determine repair priorities using the Failure Mode and Effect Analysis (FMEA) method. The data used are primary data obtained through direct observation and interviews with production personnel, as well as product defect data from January to October 2025. The analysis was conducted by identifying the type of defect, assessing the severity, occurrence, and detection levels, and calculating the Risk Priority Number (RPN) to determine defects with the highest risk. The results showed that there are three main types of defects: skin adhesion, uneven surfaces, and concrete voids. Based on the RPN calculation, void defects have the highest RPN value of 270, making them a top priority for repair. Root cause analysis using a fishbone diagram showed that void defects are influenced by human, machine, method, material, and environmental factors. Proposed improvement recommendations include increased mold inspection and maintenance, work method controls in accordance with standard operating procedures (SOPs), workforce training, and strengthening the risk-based quality control system. The implementation of the FMEA method is expected to assist the company in reducing product defect rates and sustainably improving the quality of pile production.