Enhancing reliability in garment manufacturing through FMEA and FTA

This study employs Failure Mode and Effect Analysis (FMEA) and Fault Tree Analysis (FTA) to comprehensively investigate product defects in Biyan Konveksi's manufacturing processes, one of the growing SMEs producing clothing pieces. Analyzing critical failure modes, including tear failures, stitching irregularities, sizing discrepancies, and ribbon imperfections, the research employs FTA to trace root causes, revealing the interconnected nature of these failures. The initial defect percentage, attributed to human, machine, material, and environmental factors, stood above 3%, with culottes experiencing the highest defect percentage at 3.95%. After the company implemented the enhancement measures, the defect percentage dropped significantly, reaching a range of 1 to 1.25%. Subsequently, targeted enhancement strategies are proposed, encompassing the implementation of additional worker rest breaks to alleviate fatigue, comprehensive training for new staff, and stringent machine maintenance protocols. These interventions aim to curtail tear failures, refine stitching precision, rectify sizing errors, and enhance ribbon placement. Anticipated to yield a substantial reduction in overall defect percentages, the suggested improvements position Biyan Konveksi for sustained excellence, emphasizing proactive measures to enhance worker performance and optimize manufacturing processes. The study underscores the significance of a systematic approach, combining FMEA and FTA, in diagnosing and rectifying complex failure scenarios within manufacturing environments, offering practical implications for companies aiming to fortify their competitive edge in the market.