Analisis Kualitas Hasil Mesin Bubut untuk Menurunkan Tingkat Defect Menggunakan Metode Failure Mode and Effect Analysis (FMEA) di PT XYZ
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PT XYZ menghadapi permasalahan tingginya tingkat defect pada proses pembubutan di Departemen Machining, dengan rata-rata persentase defect mencapai 12% dari total 1.716 unit produksi selama periode Juli hingga November 2025. Terdapat 6 jenis defect yang teridentifikasi, yaitu cacat dimensi, permukaan kasar, deformasi/distorsi, cacat geometri, masalah kualitas alat potong, dan kesalahan proses setup. Penelitian ini bertujuan untuk mengidentifikasi penyebab utama defect serta memberikan usulan perbaikan menggunakan metode Failure Mode and Effect Analysis (FMEA). Data dikumpulkan melalui observasi langsung, wawancara, dan dokumentasi data produksi. Hasil FMEA sebelum perbaikan menunjukkan bahwa deformasi/distorsi memiliki nilai RPN tertinggi sebesar 245, diikuti cacat dimensi sebesar 175 dan permukaan kasar sebesar 150. Setelah diterapkan perbaikan berupa standarisasi SOP, checklist produksi, pelatihan operator, kalibrasi alat ukur berkala, dan preventive maintenance, nilai RPN turun signifikan, di mana deformasi/distorsi menjadi 32 dan cacat dimensi menjadi 24. Penelitian ini menyimpulkan bahwa metode FMEA terbukti efektif sebagai alat pengendalian kualitas pada proses pembubutan di industri manufaktur, yang dibuktikan dengan penurunan substansial nilai RPN pada seluruh jenis defect. Temuan ini berkontribusi pada pengembangan ilmu teknik industri, khususnya dalam penerapan risk-based quality improvement untuk pengendalian kualitas proses permesinan.
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