Failure Mode Analysis of an Auto Palletizing System Using FMEA at PT XYZ
Abstract
The Auto Palletizing System played a role in the end-of-line production process by automatically arranging products onto pallets to maintain production continuity and operational efficiency. However, recurring failures within the system caused production downtime and reduced equipment reliability. This study aimed to identify failure modes, evaluate their risk levels, and determine improvement priorities using the Failure Mode and Effects Analysis (FMEA) method. A quantitative case study approach was employed using operational failure data collected from January to April 2026 through field observations, maintenance records, and interviews with production and maintenance personnel at PT XYZ. Each failure mode was evaluated based on Severity, Occurrence, and Detection ratings to calculate the Risk Priority Number (RPN). The results identified seven failure modes affecting the Auto Palletizing system. Five failure modes were classified as critical, namely Pallet Conveyor Jam (RPN 336), Gripper/Robot Error (288), Pallet Stuck (270), Carton Miss Orientation (256), and Carton Falling (245). These failures were identified as the primary contributors to production interruptions and system downtime. The study concluded that FMEA effectively prioritized critical failure modes and provided a systematic basis for determining improvement priorities to enhance the reliability and operational performance of the Auto Palletizing system.
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