Analysis of FMEA and FTA methods in identifying the causes of decreased quality of refined sugar products (case study: PT. Makassar Tene)

Abstract

PT. Makassar Tene is one of the manufacturing industries that produce refined sugar from raw sugar as basic materials. Most of the refined sugar production process has been carried out automatically, but it still requires regular supervision and monitoring from the operator to ensure the smoothness and accuracy of the sugar processing steps in reducing the number of defect products significantly. Failure Mode and Effect Analysis (FMEA) is a method to identify product failures based on potential causes. FMEA is used to determine the value of Risk Priority Number (RPN), then further identified as the main focus in determining the root of the potential cause using the Fault Tree Analysis (FTA). The application of FTA can provide suggestions for improvements and controls in order to help companies reduce the risk of production failure. Based on the results of the research using FMEA method, it can be seen that the process stage with the greatest risk of failure lies in the stages of sugar evaporation/crystallization and the packaging stage in the packaging bin. The next step is to identify the type of problem at each stage of the process selected using Pareto diagram so that the results show that the evaporation/crystallization stage CV deviation often happened which can produce sugar dust, while at the packaging stage the problem that often occurs is metal detection, torn sack, and sweeping sugar. Then proceed with the use of the FTA method to identify the underlying causes of each failure that arises at the chosen process stage, and the results show that most of the failures that arise are caused by operator negligence, the operation process is still done manually, and the design of operating equipment is less optimal.