Integration of Fishbone Diagram, FMEA and Taguchi Method for Optimizing Filtration and Sealing Parameters in Reducing Reject Amdk Cup 220 Ml
DOI:
10.46729/ijstm.v7i5.1491Published:
2026-10-09Downloads
Abstract
The reject rate of the 220 ml bottled drinking water (AMDK) cup line during February–April 2026 ranged from 1.41% to 5.27%, exceeding the company tolerance of 0.9%. This study aims to identify the causes of rejects, prioritize failure risks, and determine the process parameter settings that minimize rejects through an integrated framework that translates Fishbone Diagram and Failure Mode and Effect Analysis (FMEA) outputs into Taguchi experimental factors based on controllability criteria. A 5M+1E Fishbone Diagram and FMEA were applied to eleven process stages; the stages with the highest Risk Priority Number (RPN) were Micro Filter (504), Carbon Filter (384), and Sealing (216). The dominant Carbon Filter cause, media saturation, was addressed through maintenance actions because it cannot be varied as a short-term setting, whereas four controllable parameters of the Micro Filter and Sealing stages were optimized using an L9(3⁴) Orthogonal Array with three replications and a smaller-the-better characteristic. The optimal combination was A3-B1-C2-D1 (Micro Filter pressure 2.5 bar, backwash every 4 hours, sealing temperature 190°C, sealing time 1.0 s). Sealing temperature was the largest contributor (48.3%; p < 0.001), showing a non-monotonic response consistent with the heat-sealing process-window concept. The confirmation experiment yielded an S/N ratio of −12.22 dB, with 4 rejected units per run within the predicted interval of 0.95–4.38 units per run. The reject rate decreased from 1.20% to 0.40% of production output per run, representing a 66.7% reduction and remaining below the company tolerance limit of 0.9%. The study demonstrates that integrating FMEA and Taguchi methods with controllability-based factor screening enables risk priorities to be addressed through either process-setting optimization or maintenance actions.
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