The Recommendations to Improve Quality of Kitchen Set Products Using New Failure Mode and Effect Analysis and Fault Tree Analysis Methods at a Furniture Company in Bandung

Abstract

The company had a problem regarding product quality, especially on kitchen set products. Based on data for the last six months, reveals a consistent surpassing of acceptable limits for product defects every month. This causes negative consequences, encompassing both time and cost setbacks, along with a decline in consumer confidence in the company. Therefore, there was a compelling necessity to enhance the overall quality of the products. Two methodologies, New FMEA and FTA, were used to pursue the objective. A New FMEA was used to indicate which type of defect will be prioritized (using Action Priority (AP)) and a FTA was used to identify the root cause. The process of creating a kitchen set involved 11 steps, with defect occurrences noted in 8 of these steps. Based on AP high criteria, there were 6 failure modes (from 20) that will be singled out for root cause analysis through FTA. Based on the FTA, 14 root causes require attention. The proposed recommendations involved training, material inspection, material protection, periodic maintenance, operational procedures, replacement of measuring tools, and redesign of the workstation environment. Simulations were carried out to compare before and after (if the recommendations are applied) of AP by changing the occurrence and detection values. The simulation showed a decrease in the AP classification from high to moderate, suggesting a positive impact on product quality.