Production Risk Identification and Assessment of Prawn Crackers Product using Fuzzy Failure Mode and Effect Analysis: A Case Study

Abstract

PT. XYZ is an agro-industrial company that produces and exports prawn crackers. During the production process, this company faced various risks of production failure such as the non-fulfillment of product standards. Therefore, proper risk identification and assessment are needed. This study aims to identify and analyze potential failure modes (FM) of each stage of prawn cracker production using the Fuzzy Failure Mode and Effect Analysis (Fuzzy-FMEA) method. Identification was carried out to determine the potential FM, failure causes, and failure effects. Then, the assessment was carried out to determine the risk priorities based on the value of the Fuzzy Risk Priority Number (FRPN) of each identified FM. The results showed that there were 45 FM were identified from 10 stages of the production process. Priority risks for each are the risk of the raw materials not meeting the organoleptic test at the raw materials preparation stage, the risk of damage to mixing machines and equipment at the mixing stage, the risk of uncooked cuboid dough contamination at the forming stage, the risk of damage to steaming machines and equipment at the steaming stage, the risk of cooked cuboid dough damage at the pressing stage, the risk of damage pre-drying machines and equipment at the pre-drying stage, the risk of damage to the chilling machines and equipment during the chilling stage, the risk of damage to the slicing machines and equipment at the slicing stage, the risk of damage to the drying machines and equipment at the drying stage, and the risk of damage to the packaging machines and equipment at the final product packaging and storing stage.