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SPEKTRUM INDUSTRI
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ACCIDENT ANALYSIS WORK WITH FAILURE MODE AND
EFFECT ANALYSIS METHOD AT COATING SERVICE
INDUSTRY IN INDONESIA
Hasiholan Manurung1,*, Algi Fahri2, Humiras Hardi Purba3 , Hibarkah Kurnia4
1, 2, 4
Faculty of Industrial Engineering, Mercu Buana University
Jl. Meruya Selatan No 1, Kembangan, Jakarta, 11650, Indonesia
3Master of Industrial Engineering, Mercu Buana University
Jl. Meruya Selatan No 1, Kembangan, Jakarta, 11650, Indonesia
ARTICLE INFO ABSTRACT
Article history : PT. Gansa Furindo Indonesia (GFI) is a company engaged in
Received : April 2021 painting and powder coating services established in 1990. In the
Accepted : September 2021 process of making such a long and involving painting machine
and labor, it does not cover the possibility of work accidents.
There are 3 categories of work accidents: minor accidents,
Keywords: moderate accidents, and serious/major accidents. For the 3 crash
categories, it is seen how severe the injuries suffered in the work
Accident
accident. This study aims to determine the steps to prevent and
Analysis Work
Coating Services repair work accidents after knowing the categories of work
FMEA accidents that occur. This research is focused on the production
Occupational Health and Safety department, especially in the machining area where work
accidents occur due to the lack of employee awareness of Health
Safety and Environment (HSE). Work accidents include crashing
objects with a static state of 108 RPN, contact with the machine
while moving when taking the material inside the machine is 196
RPN, short circuit of 160 RPN, reverse mounting of 90 RPN and
less neat cutting in the iron cutting of 168 RPN. Therefore,
improvements are made in preventing work accidents that occur
by making the latest Standard Operational Procedure (SOP).
INTRODUCTION
Increasingly intense industry competition demands companies to produce high-quality
products; of course, the quality of the product is not apart from the role of human resources. The
level of business care for Keselamatan dan Kesehatan Kerja (K3) is still low, in addition to it is
a lack of fulfillment of requirements in the health and Work Safety, Besides safety and work
accidents are very important for the company because the impact of the accident is not only
detrimental to the employees but to the detriment of the company either directly or indirectly
directly (Mutlu & Altuntas, 2019) (Kusuma, 2017) (Qin, Xi, & Pedrycz, 2020).
The phenomenon that occurs in a company, especially in the production division, is that
employees must be able to create conditions that support comfort in work so that in these
* Corresponding author
E-mail address: [email protected]
https://doi.org/10.12928/si.v19i2.20585
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conditions employees can improve the quality and quality of output in their work. In addition,
the leadership must provide safe facilities at work so that the work accident rate can be reduced
and even should be zero accidents. The following is the number of work accidents that took
place at PT. GFI during 2019. For more details, see Figure 1.
3.5
3
2.5
2
times
1.5
1
0.5
0
January
July
February
May
April
March
June
August
September
December
November
October
Figure 1. Number of work accidents at PT Gansa Furindo Indonesia 2019
Based on Figure 1, it is found that the number of work accidents during 2019 amounted to
17 accidents and the highest was in May 2019 with 3 accidents. The categories of work
accidents found in this company are divided into three categories and one additional category,
which is almost an accident. The additional accident means that there is a potential for an
accident but it does not occur due to the availability of proper prevention. The division of work
accidents that occur can be seen in Figure 2.
3, 18% 2, 12%
5, 29% 7, 41%
Almost an Accidents Minor Accidents
Moderate Accidents Major Accidents
Figure 2. Recapitulation work accident by categories 2019
PT. GFI is a manufacturing industry company engaged in painting & powder coating
services even though PT. GFI already has K2P3 teamwork accidents still occur frequently. This
can be seen in the recapitulation of work accidents from January to December 2019, which has
been there were 17 work accidents with three categories of work accidents, namely: Almost An
Accident as much as 2, Minor Accident 7, Moderate Accident 5, Major Accidents 3. Work
accident that occurred at PT. GFI itself started with indifferent workers to the prevailing K3,
lack of concentration, and often neglect Personal Protective Equipment (PPE) when the
production process is underway; workers perceive that PPE is uncomfortable and that ignoring
it will invite danger. The cause of the work accident experienced in our company is also almost
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the same as the paper from (Karasan, Ilbahar, Cebi, & Kahraman, 2018) and (Suparjo &
Rochman, 2018).
The priority value of handling the type of work accident by using the FMEA method
(Shen, Cheung, Peng, & Haapasalo, 2009). Final result FMEA in the form of Risk Priority
Number value obtained from multiplication between severity, occurrence, and detection, which
then the result is sorted from the matter (Suryani, 2018) and (Helia & Wijaya, 2017). Based on
the references above, it is necessary to immediately resolve the work accident at PT. GFI using
the FMEA method and all improvements are included in the SOP.
RESEARCH METHOD
The research was conducted at PT. GFI located at Jl. Akasia II No.1, Sukaresmi,
Cikarang Sel., Bekasi, West Java 17530. Types of Research by survey method with a
quantitative approach that is studies that take samples directly from the population. Thus the
sample in this research is part of the research population, namely several employees who work
in the powder coating service. Data that has been owned from the results of the research are as
many as 90 people. In deciding the number of samples in this study using the Slovin formula,
namely:
𝑁
𝑛= 2
1+(𝑁.𝑒 )
(1)
n, N, and e are for number of samples, number of population, and level of error respectively.
International standards also recommend the FMEA methodology as one of the risk
analysis techniques. By applying this methodology, companies can have a systematic process to
identify potential Failure to fulfill its intended function, to identify the possible losses caused by
causes that could be eliminated, and to find the impact of Failure so that the effects can be
reduced (Firdausi, 2008; Nugroho, Suliantoro, & Utami, 2018). The steps in processing data
FMEA are as follows:
1. Identify the system
The systems observed in the study were health systems and safety (K3) at PT. GFI. One
assessment of whether the company's K3 system is running properly refers to a work
accident in the company.
2. Identify failure mode
This step will be searched for the cause of the event's Failure until a work accident.
Failure mode was obtained from categorizing the results of work accident incidents at PT
GFI.
3. Identify the failure effect
After obtained failure mode, then identified failure effect. Failure effect is defined as the
result of failure mode.
4. Identifying causes
Identify the causes of failure mode accidents at PT GFI.
5. Analyzing the severity
Severity failure mode shows the degree of seriousness of the consequences caused. A
failure mode is shown in rank one up to ten that indicate the degree of severity or danger
caused. Scaling based on Incident Severity standards Scale (Pasaribu, Setiawan, &
Ervianto, 2017) On this scale, it is clearly defined what the wounds are, diseases, social
and psychological hazards, and the dangers of equipment or machinery. The
determination of this scale is obtained from the results of discussions and interviews with
the K2P3 Team.
6. Analyzing the frequency of occurrences
Occurrence is the frequency of the cause of Failure. The specifics of a project occur and
produce a form of Failure. Occurrence uses an assessment scale of one (rarely) up to ten
(almost often). Level occurrence based on (Hidayatullah & Muliatna, 2018) (Rama Putra
Perdana, 2014)
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7. Analyzing the difficulty of detection
Detection is a measure of the ability to detect or control failures that may occur.
Detection uses an assessment on a scale of 1 to 10. These steps are almost the same as
references from (Zhai, Lv, Zhao, Wang, & Leung, 2021) and (Azad, 2018).
The steps of this research begin by collecting review literature, identifying problems, and
formulating the problem. Then the source of data is collected from interviews, distributing
questionnaires, and collecting work accident data for one year. The data that has been collected
is then processed by calculating the validation and reliability tests, if the data is valid and
reliable then proceed to the next stage and vice versa if the data is not valid then return to data
collection. After that, the data was analyzed using the FMEA method and then all the data could
be concluded and all inputs for improvement could be taken. More details can be seen in Figure
3.
Start
Literature Study
Identify Problem
Problem Formulation
Data Collection:
Interview
Questionnaire preparation
Value Data S,O,D
Work Accident Data
Validation and
Realibility
Yes
Data processing:
Recapitulation of data from the results of the questionnaire
Finding Attributes of Improvement (Customer requirements)
FMEA Identification
Preparation of Alternative Improvements
Conclusions and suggestions
End
Figure 3. Research Framework
As for processing statistical data, it can be explained by validation tests and reliability
tests (Nurmalasari, Kade, & Kamaluddin, 2014) are follows:
1. Validity Test, is the extent to which the accuracy and accuracy of measuring instruments
in carrying out functions measure An instrument is said to be valid if r-count > r-table.
2. Reliability Test, is used to know the consistency of measuring instruments. Instrument
used was reliable and consistent if the measurement is repeated. In other words, the
reliability of the device characterizes the level of consistency. Reliability testing used in
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this research is by calculating the Cronbach Alpha. Cronbach Alpha is used to find the
reliability of instruments whose scores range from multiple values or a scale (Martin et
al., 2014).
RESULTS AND DISCUSSION
In this Research, the population used is employees of PT. GFI with 90 people, while the
value of errors (e) is 10%. Based on the data, then in determining the size of the sample,
reviewed in equation (1).
90
𝑛=
1 + (90 𝑥 0.102 )
90
𝑛= = 47.37
1.9
𝑛 = 47
The study obtained the number of samples as many as 47 respondents with an error value
of 10%, where the amount is obtained from the calculation above. The results of distributing
questionnaires to several people can be seen in Table 1.
Table 1. Respondent Data
Criteria Item Number of respondents
Man 27
Gender
Woman 20
<25 years 10
25-35 years 20
Age
40-50 years 12
>50 years 5
Married 33
Status
Not married 14
Local area 40
Residence
Out of town 7
A. Safety Category Validity Test Results
Before data analysis is performed based on the results of the data collected data testing
through data validity test. Test this validity was carried out to find out whether the items
presented in the questionnaire were able to express exactly what to research. The method used is
by item analysis, where each value is in each item of the question for a variable using the
product-moment correlation formula. Condition the minimum to be considered valid is r-value >
0.248. The result of the validity test from 47 respondents with 8 question items. More details
can be seen in Table 2.
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Table 2. Validity test result
No Questions r-Calculate r-Table Result
1 Socket damaged 0.664 0.248 Valid
2 Broken socket 0.428 0.248 Valid
3 Torn hand 0.308 0.248 Valid
4 Finger scratched 0.333 0.248 Valid
Broken socket index
5 Push holder and die 0.474 0.248 Valid
broken
6 Painting machine 0.298 0.248 Valid
7 Grinding machine 0.534 0.248 Valid
8 Iron cutting machine 0.534 0.248 Valid
The result of the validity test from 47 respondents with 3 question items was another
variable. More details can be seen in Table 3.
Table 3. Recapitulation of Validity Test
No Questions r-Calculate r-Table Result
1 Occurrence 0.455 0.248 Valid
2 Severity 0.467 0.248 Valid
3 Detection 0.403 0.248 Valid
B. Reliability Test Results
The result of the reliability test from 47 respondents with 3 question items. More details
can be seen in Table 4.
Table 4. Reliability test result
No Variable Cronbach’s Alpha Result
1 Occurrence 0,598 Reliable
2 Severity 0,627 Reliable
3 Detection 0,437 Reliable
Source: Data has been processed
Based on the reliability test of 47 respondents, all question items on each of these
variables can be reliable or accurate if the Cronbach alpha value is > 0.2483 so that the data can
be used in research.
C. Failure Mode and Effect Analysis Stage
Identify failure mode obtained is a category of work accidents described above, which is
as follows:
1. Crashing into objects in a static state
2. Contact with a moving machine or material is in the machine
3. There is a short-circuit
4. Reverse hold push Installation
5. Less precise when cutting scrap
The description related to work accidents from several categories of accidents that can
occur during work can be seen in Table 5.
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Table 5. Work accident category explanation
No Categories Description
This category of accidents is due to when driving
Crashing into objects a forklift wrongly stepped on the brakes but
1
static state which was trampled by gas, finally the operator
crashing into the panel in a silent state.
Contact with a
This category of accidents is due to the lack of
moving machine or
2 concentration of employees while working and
material in the
the absence of rechecks carried out by the leader
machine
This category is a category of workability
There is a relationship
3 because the operator interacts with scraps that can
between short-circuit
cause short circuits
This category of accidents is due to the lack of
Reverse hold push
4 concentration of employees while working and
installation
the absence of rechecks carried out by the leader
Less precise when Category of work accident is due to blunt socket
5
cutting scrap knife and improper installation of the socket part
D. Identifying the Seriousness of The Consequences
Severity failure mode indicates the degree of seriousness of the consequences or effect of
the appearance of a failure mode in the network. The severity scale used is a scale of 1-10 as in
(Ririh, Sundari, & Wulandari, 2018) and (Ririh et al., 2018) shown in table 5 How serious the
impact caused by failures that cause accidents to occur work is determined by how serious the
influence is. In other words, the severity failure mode scale is determined by the severity failure
value effect. The largest severity failure effect scale is used as a scale severity failure mode as
shown in table 6.
Table 6. Severity assessment results
No Failure Mode Effect Potential Failure Mode Severity
1 Crashing objects with static state Grinding machine 6
Contact with the machine the move when Index finger hit by
2 7
retrieving materials in the machine machine
3 Short-circuit Socket is broken 5
4 Holder installation reverse Socket is broken 5
5 Less neat cutting in iron cutting Iron cutting machine 6
E. Identifying The Detection Tool For Failure Mode
In the tool identification step or how to detect the cause of the failure mode (detection),
collecting information to control the cause of Failure cause a work accident. The detection scale
used assessment results for tools or ways of managing the cause of failure mode can be seen in
Table 7. This investigation was obtained apart from field observations as well as from
discussions and interviews with Environment Health Safety (EHS) managers and staff,
operators, and managers responsible for related departments.
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Table 7. Results of detection assessments
No Failure Mode Effect Potential Cause of Failure Detection
Crashing objects with inspection of each departmental head section of
1 3
static state the ministry of employees underneath
Contact with the Socialization of the use of leather gloves as
machine on the move well as control of the stock of gloves and also
2 4
when retrieving inspection of the head of each department of
materials in the machine the department to employees underneath
Inspection of each head department to the
employees under it as well as the Socialization
3 Short-circuit of employees regarding voltage difference in 4
electric current retrieval, step down transformer
installation as well as SOP manufacturing
Holder installation inspection of each departmental head section of
4 3
Reverse the ministry of employees underneath
Less neat cutting in iron inspection of each departmental head section of
5 4
cutting the ministry of employees underneath
F. Identifying The Occurration Tool For Failure Mode
In the tool identification step or how to detect the cause of the failure mode (occurrence),
collecting information to control the cause of Failure cause a work accident. The occupation
scale used assessment results for tools or ways of managing the cause of failure mode. Then, it
is continued by assessing the risk priority number (RPN) value of the potential failure mode.
Each of the three risk factors is usually assigned a deal on a numerical scale ranging from 1 to
10. After there is a Risk Priority Number (RPN) value with the formula RPN = OxSxD, where
Occurrence (O) is the probability, Severity (S) is the seriousness of the failure, and Detection
(D) is the ability to detect failure before the impact of the failure effect manifests. The next step
is to prioritize the RPN value that has been determined (rating scale). More detail can be seen in
Table 8.
Table 8. Results of occurrence assessments and RPN result
Potential Failure
No Failure Mode Effect Occurrence RPN Rank
Effects
Crashing objects with Machine stop
1 6 108 4
static state
Contact with the
The hand will be
machine on the move
2 hurt 7 196 1
when retrieving
materials in the machine
The electricity will
3 Short-circuit go out 8 160 3
Holder installation Machine can't run
4 6 90 5
reverse
Less neat cutting in iron Spare parts can't
5 7 168 2
cutting function
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G. FMEA Results in Analysis
FMEA is a method that is used to identify potential risks for arising, determining the
impact of occupational accident risk, and remembering to mitigate such risks. The advantage of
FMEA itself is the nature of FMEA itself, which is objective because it uses the assessment of
some FMEA members, the head of the parts, and production operators. FMEA can be known
priorities handling of a type of failure mode, taking into account three aspects: severity,
occurrence, and detection. FMEA is a living document that can be updated according to the
needs of the company due to the type of Failure of new failures arise or rule changes; if in this
case, then the rules concerning the health and safety of PT. GFI The only drawback of using
FMEA is the scheduled discussion time of the FMEA team, so if later the FMEA method is
accepted company then the company needs to make a schedule to discuss the work accident
problems by the entire FMEA team and their respective relevant departments. The number of
work accidents that occur because operators do not use PPE when the production process is in
progress, they assume when using PPE they are not aware of the employee's indifference to the
PPE equipment used when working this can trigger work accidents. At the same time, failure
mode occurrence that has a value lowest is in the number four that is not done twice checking. It
is due to lack of recheck in push installation holder is not done when it should be done.
H. Proposed Improvements
For the results of the FMEA analysis of the failure detection mode, socialization to
employees about the difference in electric current-voltage, installing a step-down transformer,
and making SOPs with a detection value of 4, while for the lowest detection value of 5, re-
checking with the department leader.
There is a stage of this fix providing a solution to the problem that occurred. Proposals or
concepts of improvement in addressing work accidents by making SOP and add line type in the
production area.
CONCLUSIONS
Based on observations, data processing, and analysis, it can be concluded as follows:
There are five categories of work accidents at PT. GFI includes crashing objects with a static
state of 108 RPN, contact with the machine while moving when taking the material inside the
machine is 196 RPN, short circuit of 160 RPN, reverse mounting of 90 RPN, and less neat
cutting in the iron cutting of 168 RPN. The results of all corrective actions have been included
in the SOP and have been documented, so that all employees, both new and old, can understand
their work to eliminate the potential for work accidents. For further research, researchers will
link the potential for work accidents with the application of industry 4.0 as digitalization which
can be expected to increase productivity and eliminate work accidents in the coating service
industry.
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