Enhancing Quality Control in the Indonesian Automotive Parts Industry: A Defect Reduction Approach Through the Integration of FMEA and MSA

Sumasto, Fredy and Nugroho, Yesaya Abdi and Solih, Edwin Sahrial and Arohman, Abdul Wahid and Agustin, Desy and Permana, Al Kautsar (2024) Enhancing Quality Control in the Indonesian Automotive Parts Industry: A Defect Reduction Approach Through the Integration of FMEA and MSA. Instrumentation Mesure Métrologie, 23 (1). pp. 43-53. ISSN 16314670

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Abstract

This article presents the results of research related to measurement system improvement in the manufacturing process of part box 2ph (luggage box on a motorbike). The research used an integrated approach of Failure Mode and Effect Analysis (FMEA) and Measurement System Analysis (MSA) to identify and address critical measurement failures. Begin by identifying potential failure modes in the manufacturing process through FMEA, prioritizing high-risk failure modes, and then align these with critical measurements for subsequent evaluation. Implement MSA on the identified critical measurements, ensuring the measurement system's reliability and precision, and use the integrated results to guide corrective actions and improvements, creating a synchronized approach to enhance overall process quality. The limitation of integrating FMEA and MSA that focuses only on measurement involves limitations in addressing non-measurement aspects of potential failures, such as design issues, overall process variability, and qualitative aspects, so it may not provide a holistic picture related to the risk of failure in manufacturing processes. Key findings showed that errors in the measuring instruments, recorded on the measurement check sheets, were the focal point of urgent improvement. Root cause analysis implicated factors such as errors at the start of the project and lack of confirmation from the measurement department. In response, key initiatives involved full calibration of measuring instruments, control of the calibration schedule, appraiser training for consistency of skills and perceptions, and additional operators in quality checking and diameter sizing to reduce workload. Prior to improvement, MSA analysis revealed a significant level of uncertainty, with the Gage Repeatability and Reproducibility (GRR) value reaching 76.90%. Implementation of the improvements resulted in a dramatic reduction of GRR to 8.97%, signaling a positive transformation of the measurement system. The previously unacceptable system became reliable, with Number of Distinct Categories (ndc) values reaching 15, indicating consistency in providing information related to process changes. The results of this study provide valuable insights for further development in the manufacturing industry. By focusing on improvement strategies involving strengthening the calibration of measuring instruments, training appraisers, and adding operators, significant improvements in measurement quality and consistency can be achieved. The implications of these findings create a foundation for a proactive, data-driven approach to addressing and preventing measurement failures in manufacturing processes.

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