Quality Control Analysis of Metal Baseplate Finishing process using Statistical Process Control (SPC) and Failure Mode and Effect Analysis (FMEA): A Case Study of Indonesia Company

Abstract

Pt. Anugerah Putra Plating is one of the service companies engaged in the metal finishing industry or, more precisely Zinc Plating (zinc coating process that uses electricity) where the coating process is most widely used for small-sized goods with an extensive production scale and one of the products processed at PT. This Plating Son Award is a baseplate. Problems arising from defects are not up to the specified standards, triggering a decrease in product quality. The company produced baseplate from January 2020 to December 2020 of 53145 pcs, in that period, there were defects of 2980 pcs or 5.60%. The percentage exceeded the company's disability target of 3.50%. Based on direct observation of spaciousness and data processing using FMEA, it can be known that 4 types of defects are contained in baseplate products, namely White Rush, Oily, Black Spot and also Imperfect Coating. The most dominant defects are ranked 1 and 2, with the highest score is White Rush with a Risk Priority Number (RPN) score of 392. For this type of baseplate defect, the root of the problem is (1) Improper rounding distance, (2) unscheduled maintenance of the machine, (3) Improper chemical solution, and (4) a Dirty working environment. Proposed improvements based on the results of the analysis are as follows the types of defects White Rush: (1) Making hook hangers at a distance so that the hcl process is organized, (2) Made sterile storage space and also repair/inspection of routine machines,(3) Making the inspection sheet of chemical solution monitoring if this proposal can be carried out properly, the potential enough results that can be obtained is very -very more efficient and structured time, for the waste of costs can be emphasized to a minimum, as well as improve the quality of the product produced, so that it is expected that (estimate) the cumulative value of the company can increase by 1.8 from 5.6 -3.8 (4)Apply pickets in the respective line -each after business hours.