MITIGATING MANUAL SORTING FAILURES USING ENHANCED FMEA-BASED RISK PRIORITIZATION: CASE STUDY AT XYZ SHIPPING COMPANY
DOI:
https://doi.org/10.54783/0gk9kf31Keywords:
FMEA, operational risk, sorting process, import shipment.Abstract
This study analyzes critical failure modes in the manual sorting process at XYZ Shipping Company using the Failure Mode and Effects Analysis (FMEA) method. The research was conducted over 48 days through direct observation, operational data collection, and interviews with three experienced sorting staff. Five major failure modes were identified: human error, damaged or unreadable labels, unclear address information, incorrect postal codes, and staff fatigue. The FMEA results show that incorrect postal codes represent the highest risk, with an RPN value of 280, followed by unclear address writing (252) and damaged labels (224). These findings indicate that the manual sorting process is highly vulnerable to errors due to its dependence on operator accuracy and the lack of a validation system. The novelty of this study lies in its integration of risk prioritization with targeted mitigation strategies designed specifically for manual import-sorting operations in Indonesian logistics companies, a context that remains underexplored in existing literature. Recommended mitigation measures include implementing an automatic postal code validation system, applying waterproof label materials, and increasing sorting staff capacity to reduce fatigue. The results demonstrate that these interventions have the potential to reduce sorting-related risks by up to 45%, highlighting the practical value of applying FMEA to improve operational reliability in the logistics sector.
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