Fault Tree Analysis: A Path to Improving Quality in Part Stay Protector A Comp

• Published in: Journal Europeen des Systemes Automatises Vol. 56; no. 5; p. 757
• Main Authors: Sumasto, Fredy, Deanisa Amara Arliananda, Imansuri, Febriza, Aisyah, Siti, Indra Rizki Pratama
• Format: Journal Article
• Language: English
• Published: Edmonton International Information and Engineering Technology Association (IIETA) 31.10.2023
• Subjects: Customer satisfaction; Customers; Defective products; Defects; Manufacturing; Product quality; Raw materials
• ISSN: 1269-6935; 2116-7087
• DOI: 10.18280/jesa.560506

This research aims to enhance the quality of automotive components by employing fault tree analysis (FTA) to identify root causes and implement improvements. The FTA method was applied within an Indonesian automotive component manufacturing company specializing in producing Part Stay Protector A Comp. This component is a critical linkage point between exhaust systems and vehicle end caps, playing a crucial role in maintaining vehicle safety and performance. The data analyzed in this study, which led to the root cause determination, primarily originated from customer claims. Among these claims, a notable concern was the off-centre hole in Part Stay Protector A Comp, reflecting one of the Critical To Quality (CTQ) characteristics, with 689 instances of non-conformance. A comprehensive improvement strategy was initiated after identifying root causes through FTA. Utilizing the minimal cut sets (MCSs) method, the analysis underscored that the primary contributor to the fault was identified as (B2) Jig Detection, a critical component within the production process. The Jig Detection system serves as a quality control mechanism, verifying the alignment and conformance of the Part Stay Protector A Comp during production. This strategy focused on minimizing errors in the production method and enhancing the standardization of cup and spot tip classifications to reduce the occurrence of off-centre hole defects. The primary root cause, (B2) Jig Detection, was addressed through an innovative approach that included additional training for labour and introducing a stopper within the Inspection Jig for the Stay Protector A Comp. This strategic enhancement aimed to empower the Inspection Jig to detect off-centre defects, mitigating the recurrence of such issues. Simultaneously, addressing the issue of the non-standardized cup and spot tip usage classifications aimed to reduce the likelihood of off-centre hole defects reoccurring. The results of these improvements were systematically monitored and controlled over six months, demonstrating a significant reduction in non-centre hole defects. The subsequent results of these improvement efforts profoundly impacted product quality, ultimately reducing the count of off-centre hole defects from 689 to zero, thereby upholding the highest standards in automotive component quality.