Minimization of pipe production defects using the fmea method and dynamic system

At present, the condition of company engaged in manufacturing iron pipes receives many complaints from consumers because defective products are often found from pipe purchase orders. The risk of production failure determines how the company's process in maintaining production continuity. If the defects are high, the company receives great loss and eventually the production will be disrupted. The purpose of this study is to make a modeling to reduce the risk of failure of the pipe production process. This study identifies the risk of failure using FMEA and dynamic systems in its modeling. The identification results of defects with FMEA in a case study in an iron pipe company are obtained in the form of cracks/breaks from the welding process with the highest percentage of 50%, non-circular pipe 29%, rough surface 15%, and dimensions that do not match 6%. Several policy scenarios related to the risk of failure of the production process are tested to get a percentage of the success of the production process every month with a dynamic system. Exogenous variables from this simulation are the reliability of the machine process and the percentage of rework success. The simulation results show that the optimistic scenario has the largest final product yield of 99% and is followed by an actual simulation result of 96%, a moderate scenario of 90%, and a pessimistic scenario with a success rate of 82%. The developed model can minimize the risk of failure of the iron pipe production process and can be applied in a more complex real world.