Analysis of the Root Causes of Particle Contamination in the Cathode Coating Process Using the Seven Tools Method at PT. XYZ

Production quality is a key factor determining success in every industrial sector. To achieve these quality standards, PT. XYZ, a manufacturer of battery electric vehicles (BEVs) in Indonesia, implements a smart quality control system across its entire production line, from electrodes to formation. However, the production process involves many stages and has the potential for contamination by foreign particles. This study focuses on the cathode coating stage at PT. XYZ after copper (Cu) particles were found in electrode samples taken from the bobbin, guide roll, and top head areas. Identification was carried out using EA-300 VHX and showed that the Cu particles had characteristics consistent with indications of contamination from machine components. These initial findings were then followed up by the company through a quality audit conducted in October 2025 to determine the source of the problem and assess the actual condition of the process. This study used the SMART approach and Seven Tools to analyze the causes of contamination and formulate applicable improvements. The analysis results showed that contamination was influenced by suboptimal machine conditions, lack of cleanliness SOPs, and limitations of visual inspection in the smart quality control system. The recommended improvements focused on rearranging the coating parameters, strengthening the cleaning SOP, adding a vision camera to the unwinder, and performing regular maintenance on critical components. Through these improvements, it is hoped that the number of defects caused by particle contamination can be reduced to below the process tolerance limit and support continuous improvement in electrode production quality.