Proposed Quality Control Method for Greig Fabric Production on RRC Shuttel Weaving Machine Using FTA-FMEA to Reduce Fabric Defects at PT XYZ

Abstract

PT XYZ faces challenges in declining product quality due to production defects exceeding the optimal
tolerance limit of 2% per period for six consecutive periods. This research aims to identify and address
defects, offering action strategy recommendations to mitigate and prevent their recurrence during the
production of grey fabric on RRC shuttle loom machines. The study utilizes an integrated analysis method,
combining Fault Tree Analysis (FTA) and Failure Mode and Effect Analysis (FMEA). The research
highlights five major defect types in grey fabric products, constituting 80% cumulatively. These defects
include pickbar issues, ambrol (fraying), tears, broken threads, and skipped weaving. Twelve root causes
contributing to these defects in RRC shuttle loom production are identified and evaluated based on their
Risk Priority Number (RPN), categorized into classes A, B, and C with varying risk intensities. Two root
causes from Class A, constituting 20% cumulatively, are identified as primary defect causes. These issues
involve the fit of the weaving reed and discrepancies in the let-off and take-up motion mechanism on the
loom machine, each with an RPN value of 648. Action strategy recommendations are provided for these
two root causes, collectively contributing to 20% of the overall problem percentage. The objective is to
prevent the recurrence of the five major defect types, accounting for 80% of the cumulative percentage.
This comprehensive approach aims to rectify the identified issues, ensuring a higher standard of product
quality in the textile manufacturing process