Analysis Of The Causes Of Failure In The Ds-9c Sewing Machine Using The Fta And Fmea Methods At Pt Pesona Inti Rasa

Abstract

A malfunction of the DS-9C sewing machine on Line 2 at PT Pesona Inti Rasa has caused the production process to become suboptimal due to increased downtime. Based on data from January through December 2025, there were 230 malfunctions resulting in a total downtime of 232 hours. These conditions indicate the need for an analysis to identify the primary causes of the malfunctions. Therefore, this study aims to determine the causes of the malfunctions and prioritize their repairs. This study uses the Fault Tree Analysis (FTA) method to identify the root causes of the failures and Failure Mode and Effect Analysis (FMEA) to determine the level of failure risk. Data were collected through observations, interviews, questionnaire distribution, and the company’s failure and downtime records. The analysis began with a Pareto chart to identify priority components. Subsequently, the results of the FTA and FMEA were used as the basis for formulating improvement proposals. The results of the study indicate that the needle, thread, blade, sensor, and V-belt components are the primary causes of machine failures. The FTA results indicate that failures are influenced by human, machine, method, and material factors. The FMEA results show that several components have high Risk Priority Numbers (RPNs), making them priorities for improvement. Proposed improvements include preventive maintenance, periodic inspections, and monitoring of component usage to reduce machine failures.