Analysis of Quality Control and Product Failure Risks in Garment Manufacturing Using Statistical Quality Control (SQC) and Failure Mode and Effect Analysis (FMEA) Case Study: CV Muharram Garment Indonesia

Abstract

Quality control is an effort undertaken by a company to maintain product quality and minimize defective products during the production process. In the production process of printed T-shirts at CV Muharram Garment Indonesia, several defects were still identified, including faded prints, misaligned prints, and inappropriate colors. These defects reduce product quality and increase material waste during production. This study aims to analyze quality control, identify failure risks, and propose improvement recommendations using Statistical Quality Control (SQC), Failure Mode and Effect Analysis (FMEA), and the 5W+1H method. The SQC method was applied using check sheets, histograms, p-charts, and fishbone diagrams to analyze the types of defects, the condition of quality control, and the causes of product defects. The results showed that out of 1,380 produced units, 107 units were defective, consisting of 43 faded-print defects, 36 misaligned-print defects, and 28 inappropriate-color defects. The p-chart results indicated that there were still points outside the control limits for faded-print and misaligned-print defects, suggesting that the production process was not yet fully under statistical control. The FMEA method was used to determine risk priorities based on the Risk Priority Number (RPN). The analysis showed that the highest RPN value was found for faded-print defects at 240, followed by inappropriate-color defects at 200 and misaligned-print defects at 160. Improvement recommendations were developed using the 5W+1H method through the establishment of work standards, routine inspection of production equipment, and improved operator accuracy. These recommendations are expected to reduce defective products and improve the quality of printed T-shirt production at CV Muharram Garment Indonesia