Risk Analysis at Production Process of Hard Disk Component

Afif Al Akbar*, Tatang Akhmad Taufik

*Corresponding author for this work

    Research output: Chapter in Book/Report/Conference proceedingChapterpeer-review

    Abstract

    In the mass production of Ls products, PT XYZ has encountered substantial scrap costs due to an inability to achieve the quality standards specified by customers. The high percentage of rejected products poses the risk of sending defective items to customers, incurring a monthly cost of $40,000, and facing cancellations of customer orders over multiple periods. This research aims to analyze the potential root problems in the production process leading to a high percentage of rejects in Ls products. The method employed for analysis is Process Failure Mode and Effect Analysis (PFMEA), which assesses the occurrence, severity level, and detection of each failure mode. The Risk Priority Number (RPN) value from PFMEA indicates the highest potential risk of identification mode failure. The Pareto method and Logic Tree Analysis (LTA) are utilized to identify potential failure priorities across several categories: safety, outage, minor cases, and hidden cases. Based on the research results, the stamping process emerges as a critical area with a 50% potential for rejected products. Two failure modes in the stamping process pose risks to operator safety. Mitigation strategies are formulated to prevent the occurrence of immediate and long-term risks, involving both corrective and preventive actions. Corrective actions include direct checks or repairs and periodic inspections of equipment, along with additional support units for equipment. Preventive actions involve conducting a study of equipment reliability. The managerial response is expected to provide spare parts for tools, conduct tool reliability studies, and organize retraining sessions for operators focusing on work safety. These measures aim to steer the production process away from potential failures that could trigger product rejections.

    Original languageEnglish
    Title of host publicationStudies in Systems, Decision and Control
    PublisherSpringer Science and Business Media Deutschland GmbH
    Pages73-84
    Number of pages12
    DOIs
    Publication statusPublished - 2024

    Publication series

    NameStudies in Systems, Decision and Control
    Volume536
    ISSN (Print)2198-4182
    ISSN (Electronic)2198-4190

    Keywords

    • Logic Tree Analysis (LTA)
    • Machining manufacture
    • Process Failure Mode and Effect Analysis (PFMEA)
    • Stamping manufacture

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