FAULT TREE ANALYSIS (FTA) DAN FAILURE MODE EFFECT ANALYSIS (FMEA) UNTUK PENINGKATAN KUALITAS PRODUKSI : STUDI KASUS PADA PRODUK CUSHION, BAHAN BAKU BAN
Abstract
ABSTRAK
Menghadapi kondisi lingkungan bisnis yang tidak menentu akibat masa pandemi dan kebijakan politik secara global, perusahaan perlu melakukan evaluasi khususnya di lingkungan internal perusahaan seperti penurunan biaya produksi dan peningkatan keuntungan untuk dapat mempertahankan eksistensi dan daya saing perusahaan. Beberapa metode seperti FTA dan FMEA untuk mengidentifikasi dan mencegah terjadinya masalah dalam sistem, produk, dan proses dalam penggunaannya memiliki kelemahan masing-masing. Melalui penerapan kombinasi metode FTA dan FMEA secara recursive diharapkan faktor-faktor risiko yang mungkin terjadi dapat diidentifikasi dan usulan perbaikan dapat diterapkan sesuai dengan tingkatan prioritasnya, sehingga implementasi perbaikan berjalan dengan lebih efektif dan efisien untuk peningkatan kinerja proses sesuai dengan yang diharapkan. Dengan mengambil studi kasus pada proses produksi produk cushion di perusahaan komponen otomotif, dimana telah terjadi cacat produk terbesar pada produk cushion yaitu sebesar 36%, implementasi kombinasi antara FTA dan FMEA mampu menunjukkan potensi risiko kegagalan produksi secara hirarki dan terukur. Implementasi perbaikan yang dihasilkan dari penggunaan kombinasi FTA dan FMEA, meliputi perbaikan kompresor (prioritas utama), pelatihan keterampilan bagi karyawan (prioritas kedua), dan penerapan 5S (prioritas ketiga), menunjukkan penurunan tingkat risiko kegagalan produksi secara signifikan dari 89 (nilai rata-rata RPN sebelum dilakukan perbaikan) menjadi 64 (rata-rata nilai RPN setelah perbaikan). Terjadi penurunan sebesar 30% yang secara langsung berdampak pula pada peningkatan kualitas produksi.
Kata kunci: FMEA (Failure Modes and Effects Analysis), FTA (Fault Tree Analysis), Manajemen Risiko
ABSTRACT
Facing uncertain business environment, companies need to evaluate especially in the company's internal environment to be able maintain the company's existence and competitiveness through increased efficiency. Combination of the two methods, FTA and FMEA, risk factors can be identified and proposed improvements that can be implemented according to their priority level, so the implementation of improvements runs more effectively and efficiently to improve process performance. By taking a case study of the cushion production process in an automotive component company, which is the biggest product defect has occurred in cushion products (36%), the implementation of a combination of FTA and FMEA is able to show the improvements, including compressor repair (top priority), skills training for employees (second priority), and 5S implementation (third priority), showed a significant reduction in the level of risk of production failure from 89 to 64 (down by 30%) which directly impacted on improving production quality.
Keywords: FMEA (Failure Modes and Effects Analysis), FTA (Fault Tree Analysis), Risk Management
References
Ansori, N., & Mustajib, M. I. (2013). Sistem Perawatan Terpadu (Integreted Maintenance System). Yogyakarta: Graha Ilmu.
Cristea, G. dan Constantinescu, D.M. (2017). A comparative critical study between FMEA and FTA risk analysis methods. IOP Conf. Series: Materials Science and Engineering, 252.
Dogan, A. (2021). The effects of COVID-19 pandemic on business areas and post COVID-19 management trends. Turkish Studies - Social, 16(1), 131-156.
Franklin, B.D., Shebl, N.A., Barber, N. (2012). Failure mode and effects analysis: too little for too much? BMJ Qual Saf, 21:607e611.
Maureen S.G., Laura H.J., Igor L. 2020. Trends and applications of resilience analytics in supply chain modeling: systematic literature review in the context of the COVID-19 pandemic. Springer Nature Switzerland AG. Part of Springer Nature.
Peeters, J.F.W., Basten, R.J.I., Tinga, T. (2018). Improving failure analysis effiffifficiency by combining FTA and FMEA in a recursive manner. Reliability Engineering and System Safety, 172: 36–44.
Wessiani, N.A., Yoshio, F. (2016). Failure mode effect analysis and fault tree analysis as a combined methodology in risk management. IOP Conf. Series: Materials Science and Engineering, 337:012033.
Whiteley, M., Dunnett, S., Jackson, L. Failure Mode and Effect Analysis, and Fault Tree Analysis of Polymer Electrolyte Membrane Fuel Cells. Int. J. Hydrog. Energy, 41, 1187–1202.
Zagidullin, R., Mitroshkina, T., Dmitriev, A. (2021). Quality Function Deployment and Design Risk Analysis for the Selection and Improvement of FDM 3D Printer. IOP Conf. Series: Earth and Environmental Science, 666.
