Reducing Packaging Damage in Distribution through FMEA and 5W+1H: A Case Study in the Textile Industry

This case study examines packaging damage in the Distribution and Transportation Warehouse of PT Mulia Knitting Factory. Observation, interviews, company records, and assessments from three operational respondents were used to identify failure modes and propose controls. The reported July–September records contain 84 packaging-damage records across 1,894 shipments; the units of these two measures require confirmation before interpretation as a shipment damage rate. The revised Failure Mode and Effect Analysis (FMEA) calculates each respondent’s Risk Priority Number (RPN) as Severity × Occurrence × Detection and summarizes each failure mode by multiplying the three mean component scores. Shipment damage has the highest aggregate RPN (356.07), followed by damage during transfer to the vehicle (290.00) and storage damage (101.33). Under the explicit study-specific classification used in this revision, these are very high, very high, and high, respectively. The 5W+1H analysis links proposed customer reports, work instructions, and inspection checklists to material weaknesses, inconsistent handling, and missed defects. No post-implementation results are available; the measures are proposals whose effectiveness requires prospective evaluation. Incomplete documentation of the original rating anchors limits interpretation of the risk scores