FMEA-Based Risk Analysis to Improve Material Planning Effectiveness at PLN Indonesia Power UBP Saguling

Rafi Alviansyah; Amenda Septiala Tarigan

doi:10.30998/joti.v8.i1.2189

Authors

Rafi Alviansyah Author
Amenda Septiala Tarigan Universitas Pembangunan Nasional Veteran Jakarta Author

DOI:

https://doi.org/10.30998/joti.v8.i1.2189

Keywords:

continous improvement, Failure Mode and Effect Analysis, Inventory Control, Material Planning, Risk Management

Abstract

Effective material planning is essential to ensure uninterrupted operations in the energy sector, where supply delays may affect system reliability and maintenance schedules. PT PLN Indonesia Power UBP Saguling continues to experience recurring warehouse management challenges, particularly overstock that increases storage costs and stockout that disrupts preventive maintenance activities. This study aims to analyze risks associated with material planning and propose implementable improvement strategies. A descriptive case study approach was employed, focusing on warehouse operations at PT PLN Indonesia Power UBP Saguling. Primary data were collected through direct observation and semi-structured interviews with warehouse staff and planners, while secondary data included material planning documents, inventory records, and material usage effectiveness from January to June 2025. The analysis integrated Failure Mode and Effect Analysis (FMEA) to prioritize risks based on Risk Priority Numbers, the Fishbone Diagram to identify root causes, and the 5W+1H framework to formulate corrective actions. The findings indicate that inaccurate demand forecasting and weak inventory control were the most critical risks, with the highest priority score of 270. Recommended improvements include enhancing planning accuracy, implementing real-time monitoring through enterprise resource planning systems, and formalizing vendor coordination via Service Level Agreements. This study contributes by proposing an integrated risk-based framework for improving material planning effectiveness in the power sector.

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