Penerapan Failure Mode Effect Analysis (FMEA) untuk Identifikasi Kegagalan Mesin Tunnel Oven di Perusahaan Industri Makanan Ringan

Abstract

The snack food industry is one of the manufacturing sectors that is experiencing rapid growth, thus requiring companies to continuously improve product quality and maintain reliability in production machinery. One of the main machines used in the production process is the tunnel oven, which operates automatically for 24 hours. Continuous use of the machine increases the risk of component failure, which can jeopardize worker safety and disrupt operational continuity. This research aims to analyze the risk of failure in the subcomponents of the tunnel oven machine using the Failure Mode and Effect Analysis (FMEA) method. The analysis begins with the creation of a Functional Block Diagram (FBD) to understand the relationship between components in the system. Furthermore, the identification of failure modes, causes, impacts, and risk assessment based on three criteria, namely severity, occurrence, and detection (SOD), through discussions with expert judgment and failure data for 2022-2024. The results showed that there were 58 subcomponents with 73 potential failure modes, and 7 of them had the highest Risk Priority Number (RPN) value in each component. The subcomponents are: MCB (RPN 300), PLC (RPN 240), wiremesh belt (RPN 280), exhaust fan and blast fan drive motors (RPN 160 each), thermocouple (RPN 270), and gas leakage detector (RPN 200). These findings indicate the need to implement preventive measures through a hierarchical control approach, such as SOPs, periodic inspections, scheduled maintenance, and component replacement to improve system reliability. FMEA analysis proved to be effective in identifying risk priorities and became the basis for systematic improvement recommendations.