Developing process standard for color control in tinted products in paint manufacturing by FMEA technique

Abstract

The author has used the Failure Mode and Effect Analysis (FMEA), and Cause and Effect Diagram as the quality tools for analyzing the potential failure modes and their effects in tinted alkyd products in a systematic way. Based on the study, it was found that there are 5 major problems that extremely impact to color deviation. They include (1) Quality of raw material (2) Precision of tinting formulation (3) Inaccuracy of tinter dispensing machine (4) Insufficiency work instruction, and (5) Human error. The result of these problems lead to 2-3 times for color adjustment. Consequently, it impacts to productivity in production line. The result of analysis by means of using the Cause and Effect Diagram and FMEA technique have leaded to the establishment of the quality assurance system for tinted alkyds products which include standard work instruction, check sheet, and preventive maintenance plan. The results of implementation were the improvement in color adjustment and process time in tinting section. Based on the result, process time in tinting section reduce from 233 minutes to 147 minute per batch. Moreover, in terms of RPN (Risk Priority Number) improvement, the percentage of RPN for each criteria process comparing between before and after implementation decrease 73% to 95%.