Defect Analysis Using Pdca (Plan-do-check-action) and Fmea (Failure Mode and Effect Analysis) on Cabinets of Up (Upright Piano) (Case Study: Final Check and Repair Up – Pt. Yamaha Indonesia)

Abstract

The growth of industrial enterprises has continued as increasingly complex technologies are created and have a significant impact on the global economy. A manufacturing corporation is among the most mature business entities. Indonesia has grown to be the largest industrial base in ASEAN, contributing 20,27% to the country's overall GDP, according to investindonesia.go.id. In general, a manufacturer's objective is to create the best product possible so that the customer can profit. A manufacturing business also needs a continual development production process to ensure the survival of the business. PT Yamaha Indonesia is a manufacturing company that produces piano music instruments. There are two types of pianos produced: upright piano and grand piano. The purpose of this research is to enhance the production process at PT Yamaha Indonesia's Cabinet Case division based on an analysis of the causes of defects in order to decrease the production of defective products. The method used in this research is PDCA (Plan, Do, Check, Action) and FMEA (Failure Mode and Effect Analysis) with several supporting tools such as a Pareto diagram, fishbone diagram, 5W + 1H analysis, and check sheet. Based on the result of pareto diagram, most defect found is deformed and the cabinet with most of this defect is the top frame. The factors of this defect are shown in the fishbone diagram which consists of 6M (methods, material, measurement, machine, manpower, environment). Therefore, the recommended actions that need to be done by the company are checking every material before being sent to the next process, taking care and storing the cabinet in a proper place, and employing workers who have been well trained according to the job description. Furthermore, conducting effective training periodically and further assessments are essential to be implemented by the company.