The Implementation of FTA (Fault Tree Analysis) and FMEA (Failure Mode And Effect Analysis) Methods to Improve the Quality of Jumbo Roll Products

Abstract

PT IKPP is a manufacturing company engaged in the field of integrated pulp and paper industry with foreign investment status (PMA). Based on data obtained from September 2016 until February 2017 PT. IKPP has quality related issues on Jumbo Roll products. The product during September 2016 until February 2017, it was found defect of 1,162 (27%) of the total production of 4,346 (100%). The types of defects that occur in Jumbo Roll products are Thickness, Tensile Strength, Smoothness, Cobb Value, Porosity, Base Weight, Water Resistance, and so forth. Based on the results of analysis performed using pareto chart found 9 defects, then 3 of 9 defects with the total cumulative percentage is in the number 80%, which is the thickness of 51.89%, Tensile Strength of 25.90%, and Smoothness of 14.29%, so the main improvement focused on all three types of defects. Based on analysis of FTA method (Fault Tree Analyze) found cause of problem of defect Thickness, Tensile Strength, and Smoothness, that is influenced by some factor that is man, machine, and material. The proposed improvements that can be made for improvements in Thickness, Tensile Strength, and Smoothness are based on the largest RPN (Risk Priority Number) from the analysis of FMEA (Failure Mode and Effect Analysis) is the improvement of Thickness by performing regular maintenance on the refiner parts such as knives and refiner motor, Tensile Strength repair by setting for pulp composition (NBKP) in accordance with standard pulp composition (NBKP) on each type of paper, and improving Smoothness by setting the amperes on the refiner to match the ampere that has been set in accordance with the standard ampere on the type of paper.