Quality Control of Steel Deformed Bar Product using Statistical Quality Control (SQC) and Failure Mode and Effect Analysis (FMEA)

Abstract

Abstract The Percentage of steel deformed bar product defect in an Indonesian factory was 0.064% by 2019, where the defect percentage exceeded a limit target set by the company, which is 0.050%. This research used a Statistical Quality Control (SQC) method by applying the Seven Tools to identify the problems that caused defects in the product. The author also applied Failure Mode and Effect Analysis (FMEA) method into the production process to generate solutions for the cause of dominant defect factors. According to the calculated RPN value, the cross defect was caused the most by uncentered between top roll and bottom roll. For scratch defect, the main factor carried by Spindle Carrier that is vibrating during the rolling process. The line defect caused by a worn caliber. By implementing the recommended solution, the percentage of product defects decreased from 0.064% to 0.0075% during March to June 2020.