Analisis Risiko Produksi dengan Failure Mode and Effects Analysis (FMEA) untuk Mendukung Peningkatan Kualitas Layanan (Studi Kasus: UMKM Konveksi Topi di Sidoarjo)

Nafisovich, Ghaitsa (2026) Analisis Risiko Produksi dengan Failure Mode and Effects Analysis (FMEA) untuk Mendukung Peningkatan Kualitas Layanan (Studi Kasus: UMKM Konveksi Topi di Sidoarjo). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

UMKM XYZ merupakan usaha konveksi topi sekolah di Kabupaten Sidoarjo yang memproduksi 34.000–36.000 unit per tahun dengan strategi produksi hybrid (make-to-stock dan make-to-order). Usaha ini menghadapi tingkat komplain pelanggan sebesar 2,2%–2,4% per tahun, namun belum memiliki sistem pencatatan risiko dan kegagalan produksi secara formal. Penelitian ini bertujuan mengidentifikasi modus kegagalan (failure mode), menentukan prioritas risiko, dan merumuskan rekomendasi perbaikan menggunakan metode Failure Mode and Effects Analysis (FMEA) yang diintegrasikan dengan dua dimensi SERVQUAL, yaitu Reliability dan Tangibles. Data diperoleh melalui observasi lapangan, studi dokumentasi, serta wawancara mendalam dengan pemilik usaha dan pekerja senior. Hasil penelitian mengidentifikasi 18 modus kegagalan pada lima tahapan proses produksi, yaitu pemotongan kain, pembordiran, penjahitan lokasi utama, penjahitan rumahan, dan pengemasan, dengan nilai Risk Priority Number (RPN) berkisar antara 96 hingga 336. Berdasarkan analisis Pareto 80/20, teridentifikasi 13 modus kegagalan prioritas pada aspek Severity Reliability dan 12 pada aspek Severity Tangibles, dengan 9 modus kegagalan utama yang saling beririsan pada kedua dimensi. Nilai RPN tertinggi ditemukan pada indikator jahitan tidak presisi atau miring dan produk terkena noda. Analisis Fishbone menunjukkan bahwa mayoritas akar penyebab masalah bersumber dari ketiadaan Standar Operasional Prosedur (SOP) tertulis, belum tersedianya standar kerja penjahit rumahan, serta sistem pengendalian kualitas yang masih bersifat reaktif. Rekomendasi perbaikan yang dirumuskan meliputi lima kelompok standar kerja operasional berbasis 5W+1H, yang mencakup perencanaan produksi, pemotongan kain, pembordiran, penjahitan, pengendalian material, serta pengemasan dan pemeriksaan akhir. Seluruh rekomendasi telah divalidasi dan dinyatakan layak dari aspek modal, sumber daya manusia, maupun alur proses untuk mendukung peningkatan kualitas layanan UMKM XYZ.
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MSME XYZ is a school hat manufacturing enterprise in Sidoarjo Regency producing 34,000–36,000 units annually using a hybrid production strategy (make-to-stock and make-to-order). The business faces an annual customer complaint rate of 2.2%–2.4%, yet lacks a formal recording system for production risks and failures. This study aims to identify failure modes, determine risk priorities, and formulate corrective recommendations using Failure Mode and Effects Analysis (FMEA) integrated with two SERVQUAL dimensions, namely Reliability and Tangibles. Data were collected through field observations, documentation studies, and in-depth interviews with the owner and senior workers. The study identified 18 failure modes across five production stages: fabric cutting, embroidering, main-location sewing, home-based sewing, and packaging, with Risk Priority Number (RPN) values ranging from 96 to 336. Based on Pareto 80/20 analysis, 13 priority failure modes were identified under Severity Reliability and 12 under Severity Tangibles, with 9 overlapping primary failure modes between both dimensions. The highest RPN values were associated with imprecise or slanted stitching and stained products. Fishbone analysis revealed that the primary root causes stemmed from the absence of written Standard Operating Procedures (SOPs), lack of standardized work guidelines for home-based sewers, and a reactive quality control system. Corrective recommendations were formulated into five operational standard working groups based on the 5W+1H framework, covering production planning, fabric cutting, embroidering, sewing, material control, and packaging with final inspection. All recommendations were validated and deemed feasible in terms of capital, human resources, and process flow to support service quality improvement at MSME XYZ.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	FMEA, SERVQUAL, Konveksi, Manajemen Risiko,UMKM. FMEA, SERVQUAL, Convection MSME, Risk Management, MSME
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD61 Risk Management
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Ghaitsa Nafisovich
Date Deposited:	04 Aug 2026 01:27
Last Modified:	04 Aug 2026 01:27
URI:	http://repository.its.ac.id/id/eprint/142531

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