FUZZY FMEA APPLICATION TO IDENTIFICATION RISK IN-PROCESS PRODUCTION OF TOYOTA HI-ACE WIRING HARNESS PRODUCT

In product manufacture, the high failure rate problem of produce product is the number of product defects. Several types of defects have a high enough percentage. To solve this problem, we need to identify the failures and to get the assessment information of the three risk factors. Our research using the traditional FMEA method at the production of Wiring Harness products to shows the current condition of various modes of failure in those areas. This study focuses on implementing fuzzy FMEA to identify the potential risks that may occur along with the assembling of the Wiring Harness process. The fuzzy FMEA approach is preventing product and process problems before they occur, this paper is also expected to result in some mitigation effort that can be applied to improve the Wiring Harness production process. With the Fuzzy FMEA method, we have found the highest FRPN value that shows the highest defect such as damage insulation is 8.5, damage terminal is 8.5, and the damaged part is 8.5 and the highest RPN from the traditional FMEA is damage insulation (324).  To solve this problem, we propose to use the fishbone diagram and give suggestions for improvements to the highest failure modes that are damaged insulation.