Analisis Risiko Cacat dan Biaya Kegagalan Produk Bak Mandi dan Pot Teraso (Studi Kasus: UD. Nuraji Pot). (Analysis of Defect Risks and Failure Costs of Terrazzo Bathtub and Pot Products (Case Study: UD. Nuraji Pot)).

Niawan, Ovika Agustin Anugrah (2026) Analisis Risiko Cacat dan Biaya Kegagalan Produk Bak Mandi dan Pot Teraso (Studi Kasus: UD. Nuraji Pot). (Analysis of Defect Risks and Failure Costs of Terrazzo Bathtub and Pot Products (Case Study: UD. Nuraji Pot)). Undergraduate thesis, Universitas 17 Agustus 1945 Surabaya.

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Abstract

UD. Nuraji Pot is a trading company engaged in the production of terrazzo bathtubs and pots. In the production process, defective products are still found which cause a decrease in product quality and incur failure costs for the company. This study aims to analyze the condition of product defects using the Seven Quality Control Tools, calculate the failure costs using the Cost of Poor Quality (COPQ), and produce the results of improvement implementation using the Plan-Do-Check-Act (PDCA) method. The research data was obtained through observation, interviews, and documentation of production data for the period July–December 2025. The results of the analysis show that there are four types of defects, namely fine cracks, breaks during shipping, uneven layers, and thicknesses that do not meet standards. Based on the Pareto Diagram, fine cracks are the dominant defect with a total of 408 units or 48.57% of the total defects. Fishbone Diagram analysis shows that the main cause of fine cracks comes from the drying and mold release process that has not been standardized so that products that are not sufficiently dry experience cracks when the mold is released. The results of the COPQ calculation show that the total failure cost before repair is Rp. 23,242,000.00 consisting of repair costs of Rp. 4,385,000.00 and a residual cost of Rp. 18,857,000.00. Improvements were made through the implementation of simple Standard Operating Procedures (SOPs) at the mold drying and disposal stages. The evaluation results showed that the average number of defective products decreased from 140 units to 73 units per month, or 47.86%, while the average monthly failure cost decreased from Rp. 3,873,667.00 to Rp. 2,534,750.00, or 34.57%. The results showed that the implementation of the Seven Quality Control Tools, COPQ, and PDCA was effective in reducing product loss rates and failure costs at UD. Pot Nuraji.

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