PT PPA merupakan perusahaan yang memproduksi plastik kemasan thermoformed. Salah satu produk yang dihasilkan dan menjadi objek pada penelitian ini yaitu round drinking cups. Pada proses produksi round drinking cups terdapat banyak produk defect yang dihasilkan. Proses yang menghasilkan defect paling banyak yaitu proses thermoforming. Defect yang sering terjadi pada proses thermoforming yaitu defect diameter tidak standar dan meleyot. Adanya defect akan menimbulkan kerugian bagi perusahaan karena produk defect memerlukan rework dan sebagian harus dibuang. Penelitian ini dilakukan untuk mengurangi defect diameter tidak standar dan meleyot. Pendekatan yang digunakan pada penelitian ini yaitu menggunakan failure mode and effect analysis (FMEA). Dari data defect yang telah dikumpulkan, kemudian dilakukan penentuan defect yang menjadi prioritas perbaikan menggunakan pareto chart, selanjutnya dilakukan identifikasi penyebab-penyebab defect menggunakan cause and effect diagram dan dilakukan analisis lebih lanjut menggunakan 5 whys untuk mengidentifikasi akar penyebab defect. Hasil analisis akar penyebab defect menunjukkan terdapat 6 akar penyebab defect diameter tidak standar dan 23 akar penyebab defect meleyot. Kemudian dari akar penyebab yang telah diidentifikasi dilakukan penilaian risiko menggunakan FMEA dengan mempertimbangkan efisiensi dan downtime yang terjadi pada mesin thermoforming. Rekomendasi perbaikan diberikan berdasarkan analisis FMEA dengan nilai RPN tertinggi. Pada penelitian ini didapatkan hasil RPN tertinggi pada defect diameter tidak standar dan meleyot disebabkan permasalahan pada valve forming. Rekomendasi yang diberikan untuk mengurangi permasalahan tersebut yaitu melakukan pengecekkan valve forming, melakukan pengecekkan komponen dan pencatatan kondisi mesin secara periodik, serta meningkatkan kinerja karyawan melalui pelatihan maupun pemberian motivasi.
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PT PPA is a company that manufactures thermoformed plastic packaging. The object of this research is round drinking cups, one of the most produced products. In the production process of round drinking cups, there were many defect products produced. The process that produced the most defective products was thermoforming. The problems of quality that often occured were nonstandard diameter and dented cup defects. The defects would cause losses for the company because some of defect products required reworking and some must be discarded. This research was conducted to reduce nonstandard diameter and dented cup defects. The approach used in this research was failure mode and effect analysis (FMEA). From defects data that had been collected, priority defects were determined using pareto chart, then the potential causes of defects were identified using cause and effect diagram and further analysis was done using 5 whys to identify the root causes of the defects. The results of the root causes analysis of defects showed that there were 6 root causes of nonstandard diameter defects and 23 root causes of dented cup defects. Risk assessment was done using FMEA from the root causes that had been identified by considering the efficiency and downtime that occured on thermoforming machine. Improvement recommendations were given based on FMEA analysis with the highest RPN score. In this research the highest RPN of nonstandard diameter and dented cup defects were caused by problems in the valve forming. Recommendations that were given to reduce these problems are checking valve forming, checking machine components, documenting machine conditions periodically, and improving employee performance through training and motivation
