Redesain Cold Heading Dies Melalui Pendekatan Metode FMEA dan DFM di PT. ZYX

PT. ZYX is a foreign company automotive component sector for four-wheeled vehicles. In their third year of mass production, the production capacity reached 116 million pcs, resulting in high cost Dies purchase Cold Heading machines. This condition worsened because things such as having low lifetime and lead time purchasement range 20-40 days or more, which has potential to cause machine downtime. study aims redesign used today. Completion design uses Pareto diagram analysis, FMEA, DFM. The analysis result using FMEA method shows highest RPN value 336 with insert carbide failure that cracks during assembly. recommended corrective action make assembly support components, namely pokayoke parts, work instructions replacing inserts on Dies. results DFM change term cost. 1 unit was initially Rp. 10,247,113.00, but it dwindles 4,623,914.23. Using case dies, lock nuts, collets, stoppers resulted efficiency 54.87%.