Analysis of Improvements to the Quality of Jeans Using Seven Tools and FMEA in UKM Traders and Craft Industry in Medan City

Oct 13, 2025 by vinooalluri.com 95 views

Analysis of Improvements to the Quality of Jeans Using Seven Tools and FMEA in UKM Traders and Craft Industry in Medan City

Introduction

The UKM Traders and Craft Industry Unit of Medan City Crafts, which specializes in producing jeans, faces significant challenges due to the high level of product defects exceeding the company's tolerance limit of 3%. This issue not only results in financial losses but also affects the company's reputation. To address this problem, an in-depth analysis is required to identify the causes of defects and implement the right solutions.

Overcoming Defects of Jeans Products: Application of Seven Tools and FMEA in Medan City UKM

The research team employed the application of seven tools and Failure Mode and Effects Analysis (FMEA) to identify and analyze the problem of product defects in jeans. The seven tools used in this study include:

Check Sheet: A data collection tool used to gather information on production dates and defects.
Pareto Diagram: A statistical tool used to identify the most common causes of defects.
Cause-and-Effect Diagram: A visual tool used to identify the main factors contributing to product defects.
Control Chart: A statistical tool used to monitor and control the production process.

Meanwhile, FMEA is used to evaluate the potential failure and its impact on the production process.

Revealing the Cause of Product Defects

The analysis of data obtained from the check sheet reveals that several production dates have a number of defects exceeding the company's tolerance limit. The results of the Pareto Diagram analysis show that defects in the sewing process are the main causes of defective products. The cause-and-effect diagram identifies five main factors that cause product defects, namely:

Human Factors: Worker skills and knowledge in the production process.
Materials: Quality of raw materials received from suppliers.
Environment: Work environment conditions, such as organization, cleanliness, and comfort.
Machines: Maintenance and performance of machinery.
Work Methods: Effectiveness and efficiency of work methods.

The control chart analysis shows that the production process is not controlled and requires improvement to achieve the desired quality target.

Determine Priority Improvement with FMEA

FMEA is used to analyze potential risks that can cause defects in the product. Through the calculation of risk priority number (RPN), a ranking of factors causing defects from the highest to the lowest is determined.

The results of the FMEA analysis show that the human factor has the highest RPN (144), followed by material factors (125), work methods (120), work environment (108), and machinery (90).

Effective Solution

Based on the results of the analysis, the UKM of the Medan City Traders and Crafts Industry Unit needs to take several steps to improve, namely:

Human Factors: Provide training to workers to improve skills and knowledge in the production process, as well as apply Standard Operating Procedure (SOP) which is clear to minimize errors.
Material Factors: Check the quality of the raw materials received from suppliers to ensure the quality of the material according to the standard.
Work Methods: Applying a more effective and efficient work method, as well as evaluating and revising existing SOPs.
Working Environment: Make an improvement in the work environment so that it is organized, clean, and comfortable to increase worker productivity.
Machine: Doing routine maintenance against the engine to maintain its performance and minimize the potential for damage.

Conclusion

The application of seven tools and FMEA gives a clear picture of the causes of disabilities of jeans products in UKM Traders and Crafts Industries in Medan City. Solutions that are right on target and structured based on the results of the analysis are expected to improve product quality, reduce defects, and increase company profits.

Recommendations

Based on the findings of this study, the following recommendations are made:

The UKM of the Medan City Traders and Crafts Industry Unit should implement the solutions proposed in this study to improve product quality and reduce defects.
The company should provide training to workers to improve their skills and knowledge in the production process.
The company should check the quality of the raw materials received from suppliers to ensure the quality of the material according to the standard.
The company should apply a more effective and efficient work method, as well as evaluate and revise existing SOPs.
The company should make an improvement in the work environment so that it is organized, clean, and comfortable to increase worker productivity.
The company should do routine maintenance against the engine to maintain its performance and minimize the potential for damage.

Limitations of the Study

This study has several limitations, including:

The study only focuses on the UKM of the Medan City Traders and Crafts Industry Unit and may not be generalizable to other companies.
The study only uses the seven tools and FMEA to analyze the causes of product defects and may not consider other factors that may contribute to defects.
The study only proposes solutions based on the results of the analysis and may not consider other potential solutions.

Future Research Directions

Future research should consider the following directions:

Conducting a similar study in other companies to generalize the findings of this study.
Considering other factors that may contribute to product defects, such as supplier quality and customer requirements.
Proposing more comprehensive solutions that consider multiple factors and stakeholders.

References

[1] ISO 9001:2015. Quality management systems - Requirements.
[2] FMEA (Failure Mode and Effects Analysis). A method for identifying and evaluating potential failures in a product or process.
[3] Seven tools of quality. A set of statistical tools used to analyze and improve quality in a product or process.

Appendices

Appendix A: List of references used in this study.
Appendix B: List of abbreviations used in this study.
Appendix C: List of tables and figures used in this study.
Q&A: Analysis of Improvements to the Quality of Jeans Using Seven Tools and FMEA in UKM Traders and Craft Industry in Medan City

Introduction

The analysis of improvements to the quality of jeans using seven tools and FMEA in UKM Traders and Craft Industry in Medan City has provided valuable insights into the causes of product defects and potential solutions. In this Q&A article, we will address some of the most frequently asked questions related to this study.

Q1: What are the main causes of product defects in jeans?

A1: The main causes of product defects in jeans are human factors, materials, environment, machines, and work methods. These factors were identified through the application of the seven tools and FMEA.

Q2: How can the UKM of the Medan City Traders and Crafts Industry Unit improve product quality?

A2: The UKM of the Medan City Traders and Crafts Industry Unit can improve product quality by implementing the solutions proposed in this study, including providing training to workers, checking the quality of raw materials, applying a more effective and efficient work method, improving the work environment, and doing routine maintenance against the engine.

Q3: What is FMEA and how is it used in this study?

A3: FMEA is a method for identifying and evaluating potential failures in a product or process. In this study, FMEA is used to analyze potential risks that can cause defects in the product and to determine the priority of improvement.

Q4: What are the benefits of using the seven tools and FMEA in this study?

A4: The benefits of using the seven tools and FMEA in this study include identifying the causes of product defects, determining the priority of improvement, and proposing solutions that are right on target and structured based on the results of the analysis.

Q5: How can the results of this study be applied to other companies?

A5: The results of this study can be applied to other companies by considering the causes of product defects and potential solutions proposed in this study. However, it is essential to note that the study only focuses on the UKM of the Medan City Traders and Crafts Industry Unit and may not be generalizable to other companies.

Q6: What are the limitations of this study?

A6: The limitations of this study include only focusing on the UKM of the Medan City Traders and Crafts Industry Unit, only using the seven tools and FMEA to analyze the causes of product defects, and only proposing solutions based on the results of the analysis.

Q7: What are the future research directions?

A7: Future research directions include conducting a similar study in other companies to generalize the findings of this study, considering other factors that may contribute to product defects, and proposing more comprehensive solutions that consider multiple factors and stakeholders.

Q8: What are the references used in this study?

A8: The references used in this study include ISO 9001:2015, FMEA (Failure Mode and Effects Analysis), and the Seven tools of quality.

Q9: What are the appendices used in this study?

A9: The appendices used in this study include a list of references, a list of abbreviations, and a list of tables and figures.

Q10: What is the conclusion of this study?

A10: The conclusion of this study is that the application of the seven tools and FMEA gives a clear picture of the causes of disabilities of jeans products in UKM Traders and Crafts Industries in Medan City. Solutions that are right on target and structured based on the results of the analysis are expected to improve product quality, reduce defects, and increase company profits.

References

[1] ISO 9001:2015. Quality management systems - Requirements.
[2] FMEA (Failure Mode and Effects Analysis). A method for identifying and evaluating potential failures in a product or process.
[3] Seven tools of quality. A set of statistical tools used to analyze and improve quality in a product or process.

Appendices

Appendix A: List of references used in this study.
Appendix B: List of abbreviations used in this study.
Appendix C: List of tables and figures used in this study.