Analysis Of Defects In Inner and Outer Door Products of Innova Zenix In The Stamping Process Using The Pdca Approach In The Automotive Industry
DOI:
https://doi.org/10.70182/jca.v2i5.1765Keywords:
Defect Reduction, Failure Mode And Effects Analysis, Industrial Engineering, Process Quality Control, Stamping ProcessAbstract
This study analyzed defect occurrences in the inner and outer door products of Innova Zenix during the stamping process at PT. XYZ, an automotive manufacturing company located in Karawang Industrial Estate, West Java, against the background of high defect rates recorded between January and June 2025. The research aimed to identify the main factors causing recurrent defects, especially the dominant ding defect, and to formulate improvement proposals based on the integration of Failure Mode and Effects Analysis (FMEA) and the Plan–Do–Check–Action (PDCA) cycle. A mixed‑methods case study approach was employed, involving direct observation at line 1 stamping, semi‑structured interviews with operators, quality control staff, and maintenance technicians, and documentation of defect and production records. Data were analyzed thematically with 5W+1H, supported by Pareto and fishbone diagrams, and quantitatively through FMEA to calculate Risk Priority Numbers (RPN). The results revealed that ding defects were the most frequent (705 units), with the highest RPN (432) occurring on the failure mode of rough die surfaces, driven by human factors (insufficient diligence in die inspection) and machine factors (unstable press pressure and non‑optimal die conditions). In conclusion, the integration of FMEA and PDCA provided a systematic framework for continuous improvement that reduced defect rates, enhanced stamping process stability, and supported achievement of zero‑defect standards in similar automotive manufacturing settings.
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