Analisis Root Cause Defect Bubbling Placket pada Produksi Kemeja Style PR-LS Shirt di PT Ambassador Garmindo II Ekspor Menggunakan Fishbone Diagram dan FMEA
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Kualitas produk merupakan faktor penting dalam menjaga kepercayaan buyer pada industri garmen berorientasi ekspor. Salah satu defect yang memengaruhi kualitas visual produk pada produksi kemeja adalah bubbling placket, yaitu munculnya gelembung pada bagian placket akibat ketidaksempurnaan proses adhesi interlining. Penelitian ini bertujuan untuk menganalisis akar penyebab defect bubbling placket pada produksi PR-LS Shirt di PT Ambassador Garmindo II menggunakan pendekatan Fishbone Diagram, 5 Why dan Failure Mode and Effect Analysis (FMEA). Penelitian dilakukan pada line sewing H6 selama Februari–Mei 2025 menggunakan metode observasi langsung, wawancara dengan operator, QC, dan supervisor, serta studi dokumen laporan inspeksi produksi. Data menunjukan output produksi sebesar 5.565 pcs per bulan dengan rata-rata defect rate sebesar 4,1%. Hasil Diagram Pareto menampilkan bubbling placket sebagai salah satu defect dominan dengan proses rework yang relatif kompleks sehingga dipilih sebagai fokus penelitian. Analisis Fishbone Diagram menunjukkan bahwa defect bubbling placket dipengaruhi oleh belum tersedianya panduan visual bagi operator terkait teknik pemasangan interlining dan tekanan target produksi yang tinggi sebagai faktor manusia, ketidakstabilan suhu mesin fusing dan kerusakan elemen pemanas sebagai faktor mesin dan penurunan kualitas adhesive interlining akibat penyimpanan yang kurang sesuai sebagai faktor material. Hasil analisis 5 Why menunjukkan bahwa akar penyebab defect berkaitan dengan belum optimalnya sistem pengendalian parameter proses fusing dan visual standard pemasangan interlining. Hasil analisis FMEA menunjukkan bahwa suhu mesin fusing yang tidak stabil memiliki nilai Risk Priority Number (RPN) tertinggi sehingga menjadi faktor paling kritis dalam munculnya defect bubbling placket. Usulan tindakan perbaikan difokuskan pada standarisasi parameter proses fusing, perawatan dan kalibrasi mesin secara berkala, penyediaan visual guide pada workstation, serta pengawasan kondisi penyimpanan material interlining. Penelitian ini diharapkan dapat menjadi acuan dalam pengendalian mutu dan pengurangan defect pada industri garmen ekspor.
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