Combination of FTA and FMEA methods to improve efficiency in the manufacturing company

Abstract

Toroidal is an inductor with an O-ring core. In 2021 there was an increase in the percentage of toroidal disability, namely the highest percentage of disability at 2.78%, while in 2020 the highest percentage of disability was only 1.33%. Therefore, companies need to make improvements to the quality of their products to prevent a continuous rise in the percentage of defects over time. This study aims to propose an enhancement to reduce/prevent defects in toroidal inductor products. The method used is the Fault Tree Analysis (FTA) and Failure Mode and Effect Analysis (FMEA). The FMEA method is utilized to reduce flaws that occur by considering the value of the risk priority number (RPN). The FTA method is used to identify possible defects by applying analysis of the fault tree description. The results of this study are that improvements should be focused on the failure mode of the wound wire because it gets the highest RPN value of 216 with the cause being less focused workers, while the lowest RPN value is on the red pin failure mode of 56 with the cause of no sandpaper changing schedule. From the results of the study, several suggestions for improvements were made in the form of increasing supervision for workers, increasing rest periods, conducting training, installing display limits for stripping, repairing stripping machines, replacing vise, repairing worktables, and making a schedule for sandpaper replacement prevents the defect. Companies must make improvements to human flows and ensure tools and materials are in optimal condition.