Quality Control Analysis of Export-Grade Barramundi (Lates calcarifer) Fillet Using Statistical Process Control and Failure Mode and Effect Analysis

Abstract

Ensuring consistent product quality in export-oriented seafood processing is essential to comply with international standards and maintain market competitiveness. This study evaluates the quality control performance of export-grade barramundi (Lates calcarifer) fillet production using an integrated approach combining Statistical Process Control (SPC) and Failure Mode and Effect Analysis (FMEA). The research was conducted over a seven-month period (August 2025-February 2026) at a seafood processing company in Denpasar, Bali, Indonesia. SPC tools, including check sheets, Pareto diagrams, p-control charts, and fishbone diagrams, were applied to monitor process stability and identify dominant defect types. The results indicated four primary defects: improper fillet cutting (42.65%), vacuum leakage (35.29%), labeling errors (10.29%), and residual scales (11.76%). The p-chart analysis showed that the process remained statistically under control, although defect proportions increased during peak production in December. Pareto analysis revealed that improper cutting and vacuum leakage contributed nearly 78% of total defects, highlighting critical control points in processing and packaging stages. FMEA further identified vacuum leakage as the highest-risk failure mode, with a Risk Priority Number (RPN) of 2160 due to its severe impact on product shelf life and export compliance. The integration of SPC and FMEA proved effective in distinguishing statistically stable processes from high-priority operational risks. The study demonstrates that combining quantitative monitoring with structured risk assessment enhances decision-making, supports targeted corrective actions, and strengthens quality assurance systems in seafood fillet processing industries.