Failure Analysis of the Stamping Process to Reduce Defective Products Using Failure Mode and Effects Analysis (FMEA)

Abstract

Digital technology today,particularly information technology plays a crucial role in improving efficiency and productivity in the manufacturing sector, where the sustainability and effectiveness of production processes are largely determined by the reliability of machinery, especially in precision metal casting. PT XYZ Company, which produces semi-finished components made of iron/steel and aluminum for electronic devices, continues to face challenges in the form of high rates of product rejection and tool damage, caused by various factors such as clogged oil filters, excessive oil flow, and failures of the missfeed sensor to detect material. These issues are not merely technical problems but are also influenced by factors related to people, materials, machinery, and methods such as a lack of operator training, the use of used or contaminated oil, manual control systems, and the absence of routine monitoring all of which ultimately lead to reduced productivity, increased maintenance costs, and delivery delays. Furthermore, the absence of an early detection system and structured analysis makes it difficult to comprehensively identify the root causes of problems; therefore, the Failure Mode and Effects Analysis (FMEA) method serves as a relevant approach to proactively identify potential failures, analyze their impacts, and prioritize corrective actions based on the Risk Priority Number (RPN). This study aims to improve machine reliability through the application of FMEA and the development of structured corrective actions to support a more effective preventive maintenance strategy. Through this data-driven and risk-priority-based approach, it is expected that the company can minimize downtime, reduce tool rejection and damage rates, and strengthen a culture of continuous improvement as the foundation for future strategic decision making.