Title: DESIGN TO IMPROVE THE QUALITY OF RAIL ROAD BEARING PRODUCTS USING THE FMEA (FAILURE MODES AND EFFECT ANALYSIS) METHOD AT PT. WIJAYA WORKS OF CONCRETE
Author: ARYO HIMANDA RAMADHANI
Affiliations : Master of Management Science Program, Faculty of Economics and Business, Universitas Airlangga , Surabaya, Indonesia
Publisher: Universitas Airlangga
Abstract
PT. Wijaya Karya Beton is one of the large companies in Indonesia that produces concrete. One of the superior products from PT. Wijaya Karya Beton is a railroad sleeper. The aim of this research is to identify product failures in railway sleepers using the Failure Modes and Effect Analysis (FMEA) method. By using this method, you can identify and detect forms of failure that have the potential to cause the product to become defective or fail. Thus, potential forms of failure can be suppressed through anticipatory steps based on risk priorities. This research focuses on stages of the production process that are prone to failure, including the stages of assembly and installation of reinforcement, casting, and product stacking. From the research results, it was found that the number of failures of railway bearing products that cracked in the anchor plate area during 2011 was seven units out of total production of 35,915 units. Furthermore, six units of product were caused by spots in the concrete and three units were caused by chipping and cracking extending across the anchor area. Lastly, caused by shoulder collapse or slanting and small malls passing 3mm each for one product unit. In this research, the Pareto diagram shows that the cause of failure is dominated by bent tensile bolts with a percentage of 39%. To improve quality, use the FMEA method by looking for the Risk Priority Number (RPN) value which is obtained by multiplying the severity, occurrence and detection numbers. The causes that have a high risk come from the material and method category, because they have an RPN value above 150. So, process improvements that can be made are to carry out strict selection of the materials that will be used in the production process, materials that do not meet the standards should be replaced. Apart from that, it is also necessary to provide an explanation of existing SOPs and good work methods by instilling awareness about the importance of quality to all employees and motivating employees to improve product quality. It is hoped that using the FMEA method will be an option to reduce product failure by focusing on overcoming factors that have the potential to cause product failure.
Keywords: Failure modes and effect analysis, railway bearings, product failure, quality improvement
