Analysis of Defects in White Crystal Sugar Products at XYZ Sugar Factory using Fault Tree Analysis (FTA) and Failure Mode and Effect Analysis (FMEA)

Abstract

XYZ Sugar Factory is a manufacturing company that produces processed sugar cane with the main product being white crystal sugar of the Super High Sugar (SHS) type. The problem found at the XYZ Sugar Factory was that there were defects in white crystal sugar products amounting to 7,359.1 tons with a defect percentage of 11.12%. This study aims to determine the types and causes of defects, as well as suggestions for improvements. The methods used are Fault Tree Analysis and Failure Mode and Effect Analysis. The results of the research show that the types of defects that occur in white crystal sugar products are sugar color defects and sugar grain size defects. One of the causes of sugar color defects is excessive levels of additional raw materials, while one of the causes of sugar grain size defects is the insufficient cooking duration of the sugar crystals. The results of FMEA calculations obtained the highest RPN value, namely sugar color defects with an RPN value of 140 and then grain size defects with an RPN value of 120. Proposed improvements for the company are to make appropriate measurements for additional raw materials to help with the production process and provide more routine training to employees regarding the use of machines. production.