Factors Causing Disability Based on FMEA

Oct 13, 2025 by wbrum.org 145 views

Introduction

PT. Hadi Baru, a rubber processing company that relies on rubber tree sap as a raw material, is struggling to face the problem of the high number of crumb rubber SIR 20 product. Although the company has implemented a quality control program, there are still 20% defective products at the end of the production process. This results in significant financial losses for the company. The problem of defective products not only affects the company's financial performance but also its reputation and customer satisfaction. Therefore, it is essential to identify the main factors causing product disability and implement effective solutions to overcome this problem.

Background of the Study

PT. Hadi Baru is a rubber processing company that has been operating for several years. The company relies on rubber tree sap as a raw material and produces crumb rubber SIR 20 products. However, the company has been facing a significant problem of defective products, which has resulted in financial losses. The company has implemented a quality control program, but the problem persists. Therefore, it is essential to conduct a study to identify the main factors causing product disability and implement effective solutions to overcome this problem.

Methodology

This study used the DMAIC SIX SIGMA methodology to analyze the main factors causing product disability. The DMAIC methodology is a problem-solving approach that consists of five phases: Define, Measure, Analyze, Improve, and Control. The study was conducted during July 2012, and 26 product samples were analyzed. The analysis showed that pri levels and dirt levels were the dominant factor of disability. The Sigma value of 2.46, indicating that the production process was far from ideal. The Kolmogorov Smirnov Test's normality test also shows that data is normally distributed, so that the results of research can be relied upon.

Factors Causing Disability Based on FMEA

FMEA (Failure Mode and Effects Analysis) analysis identifies the main causes of crumb rubber sir 20 disability as follows:

Low Raw Material Quality

Raw materials containing dirt such as wood crumbs, soil, and others are the main factors that cause disability. The use of low-quality raw materials can lead to defects in the product, which can result in financial losses for the company.

Unclean Washing Process

The use of dirty water in the washing process also contributes to increasing dirt and defects in the product. The washing process is an essential step in the production process, and the use of clean water is crucial to remove dirt and improve product quality.

Imperfect Drying and Drying Process

Drying time that is less than 7 days causes the product is not completely dry and increases the risk of disability. The drying process is a critical step in the production process, and the use of a perfect drying process is essential to eliminate moisture and prevent disability.

Solution to Improve Product Quality

This study produced a number of recommendations to overcome the problems of defective products and improve the quality of crumb rubber sir 20:

Tight Raw Material Selection

PT. Hadi only needs to improve the selection process of raw materials by paying attention to the level of dirt contained in it. The use of high-quality raw materials can lead to defects in the product, which can result in financial losses for the company.

Washing with Clean Water

The use of clean water in the washing process is very important for removing dirt and improving product quality. The washing process is an essential step in the production process, and the use of clean water is crucial to remove dirt and improve product quality.

Perfect Drying Process

PT. Hadi only needs to ensure the drying process is carried out perfectly for 7-12 days to eliminate moisture and prevent disability. The drying process is a critical step in the production process, and the use of a perfect drying process is essential to eliminate moisture and prevent disability.

Periodic Inspection of the Machine

Periodic inspection on the production machine will reduce the risk of damage and improve product quality. The use of a well-maintained machine can lead to defects in the product, which can result in financial losses for the company.

Increasing Awareness and Commitment of Workers

Awareness and commitment of workers in carrying out their duties well are key factors in producing quality products. The use of a well-trained and motivated workforce can lead to defects in the product, which can result in financial losses for the company.

Conclusion

Application of Six Sigma Methodology provides an effective solution to overcome the problem of high number of crumb rubber SIR 20 defective products at PT. New Hadi. By carrying out the recommendations given, the company can reduce the level of disability, improve product quality, and reduce financial losses. Increased awareness and commitment of workers is also an important factor in achieving these goals.

Recommendations

Based on the findings of this study, the following recommendations are made:

PT. Hadi should improve the selection process of raw materials by paying attention to the level of dirt contained in it.
PT. Hadi should use clean water in the washing process to remove dirt and improve product quality.
PT. Hadi should ensure the drying process is carried out perfectly for 7-12 days to eliminate moisture and prevent disability.
PT. Hadi should conduct periodic inspection on the production machine to reduce the risk of damage and improve product quality.
PT. Hadi should increase awareness and commitment of workers in carrying out their duties well to produce quality products.

Limitations of the Study

This study has several limitations. The study was conducted on a small sample size, and the results may not be generalizable to other companies. Additionally, the study only focused on the factors causing product disability and did not consider other factors that may affect product quality.

Future Research Directions

Future research should focus on the following areas:

Conducting a larger-scale study to confirm the findings of this study.
Investigating other factors that may affect product quality.
Developing a more comprehensive quality control program that includes all aspects of the production process.

By addressing these limitations and future research directions, this study can provide a more comprehensive understanding of the factors causing product disability and provide effective solutions to overcome this problem.

Introduction

In our previous article, we discussed the problem of crumb rubber SIR 20 defective products at PT. New Hadi and how the application of Six Sigma methodology can provide an effective solution to overcome this problem. In this article, we will answer some frequently asked questions (FAQs) about the study and its findings.

Q: What is the problem of crumb rubber SIR 20 defective products at PT. New Hadi?

A: The problem of crumb rubber SIR 20 defective products at PT. New Hadi is a significant issue that affects the company's financial performance, reputation, and customer satisfaction. The company has implemented a quality control program, but the problem persists, resulting in 20% defective products at the end of the production process.

Q: What is the Six Sigma methodology, and how does it help to overcome the problem of crumb rubber SIR 20 defective products?

A: The Six Sigma methodology is a problem-solving approach that consists of five phases: Define, Measure, Analyze, Improve, and Control. It helps to identify the root causes of defects and implement effective solutions to overcome them. In this study, the Six Sigma methodology was applied to analyze the main factors causing product disability and implement effective solutions to overcome this problem.

Q: What are the main factors causing product disability, and how can they be overcome?

A: The main factors causing product disability are low raw material quality, unclean washing process, imperfect drying and drying process, and lack of periodic inspection of the machine. These factors can be overcome by improving the selection process of raw materials, using clean water in the washing process, ensuring the drying process is carried out perfectly, and conducting periodic inspection on the production machine.

Q: How can PT. New Hadi improve the quality of its products and reduce the level of disability?

A: PT. New Hadi can improve the quality of its products and reduce the level of disability by implementing the recommendations given in this study. These recommendations include improving the selection process of raw materials, using clean water in the washing process, ensuring the drying process is carried out perfectly, and conducting periodic inspection on the production machine.

Q: What is the role of awareness and commitment of workers in producing quality products?

A: Awareness and commitment of workers play a crucial role in producing quality products. Workers who are aware of the importance of quality and are committed to their duties can help to reduce the level of disability and improve product quality.

Q: What are the limitations of this study, and what are the future research directions?

A: This study has several limitations, including a small sample size and a focus on only one aspect of the production process. Future research should focus on conducting a larger-scale study, investigating other factors that may affect product quality, and developing a more comprehensive quality control program.

Q: How can PT. New Hadi implement the recommendations given in this study?

A: PT. New Hadi can implement the recommendations given in this study by conducting a thorough analysis of its production process, identifying the root causes of defects, and implementing effective solutions to overcome them. This may involve training workers, improving the selection process of raw materials, and conducting periodic inspection on the production machine.

Conclusion

In conclusion, the application of Six Sigma methodology provides an effective solution to overcome the problem of crumb rubber SIR 20 defective products at PT. New Hadi. By implementing the recommendations given in this study, PT. New Hadi can improve the quality of its products, reduce the level of disability, and increase customer satisfaction.