Implementation Of Root Cause Analysis And 5w On Dorado Products To Reduce Product Defects
DOI:
https://doi.org/10.62375/jmrib.v4i2.807Keywords:
Dorado products fishbone diagram five whysAbstract
The growth of the manufacturing sector requires companies to continuously ensure and enhance product quality in order to remain competitive and satisfy customer expectations. At PT Ennovi Integrated Engineering Servising Batam, quality problems were identified in Dorado products, particularly during the manual damper (sticker) installation process. Production records from March to May 2025 indicated that defects accounted for 27% of total output, with porosity, bent pins, and missing pins being the most frequently observed defects.This research was conducted to classify the types of defects, analyze their root causes, and propose improvement actions to minimize the rejection rate of Dorado products. The study employed Root Cause Analysis (RCA) supported by Pareto charts, fishbone diagrams, and the Five Whys technique. Data were gathered through direct observation of the production process, interviews with relevant personnel, and examination of internal production reports.The findings reveal that the dominant causes of defects are associated with human factors, work methods, and workplace conditions, particularly the absence of appropriate tools and the lack of standardized procedures for sticker installation. Improvements were implemented by developing a dedicated jig for sticker application and refining the work instructions. These measures successfully reduced the defect rate and improved production performance. Therefore, the use of Root Cause Analysis proved to be an effective approach for identifying quality issues and supporting continuous improvement in manufacturing operations.
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