Failure Analysis of Paving Block Production Using Failure Mode and Effects Analysis Method at UD. Baja Mulia

Yohana Dian Putri; Syukriah; Sherly Humaira Stanzah

Authors

Yohana Dian Putri Universitas Malikussaleh Author
Syukriah Universitas Malikussaleh Author
Sherly Humaira Stanzah Universitas Malikussaleh Author

Keywords:

paving block, failure mode and effect analysis, kaizen, product failure

Abstract

UD. Baja Mulia is a paving block manufacturing company that continues to experience product failures during its production process, with a daily failure rate ranging from 5% to 15%, exceeding the company’s defect tolerance limit of 2%. This study aims to analyze the failure risk in the paving block production process using the Failure Mode and Effects Analysis (FMEA) method and to develop improvement proposals using the Kaizen method through the 5W1H approach. A quantitative descriptive approach was employed, and data were collected through observation, interviews, and documentation. The analysis results indicate that grivis failure has the highest Risk Priority Number (RPN) value of 343, making it the primary priority for improvement. The causes of failure are associated with human, method, material, machine, and environmental factors. The proposed improvements focus on arranging paving blocks on wooden pallets to prevent contact between products, providing on-the-job training for new operators, and implementing mixture testing as a standard inspection procedure before the molding process. These improvement proposals are expected to reduce the risk of grivis failure in the paving block production process.

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