Optimizing Operations: Evaluating Overall Equipment Effectiveness (OEE) And Failure Mode Effect Analysis (FMEA) For Muratec Qpro Ex Winding Machines at PT XYZ

PT. XYZ is a leading manufacturing company that focuses on the textile industry, especially in producing yarn from cotton, polyester, and rayon raw materials. Even though it has adequate infrastructure and machines, the performance of the Winding machines at PT. XYZ is not yet optimal, characterized...

Full description

Saved in:
Bibliographic Details
Published in:Journal of physics. Conference series 2024-12, Vol.2928 (1), p.012013
Main Authors: Pitoyo, Djoko, Azwar, Ade Geovania, Aprilia, Anggi
Format: Article
Language:English
Subjects:
Availability
Breakdown
Breakdowns
Control equipment
Cotton
Defective products
Defects
Downtime
Effectiveness
Failure modes
Impact analysis
International standards
Maintenance
Optimization
Plant layout
Raw materials
Rayon
Winding
Online Access:Get full text
Tags: Add Tag
No Tags, Be the first to tag this record!
Description
Summary:PT. XYZ is a leading manufacturing company that focuses on the textile industry, especially in producing yarn from cotton, polyester, and rayon raw materials. Even though it has adequate infrastructure and machines, the performance of the Winding machines at PT. XYZ is not yet optimal, characterized by machine downtime problems and defective products. This research aims to identify and analyze the performance of Winding machines to find the root of the problem and formulate the necessary follow-up actions. The analysis method used is Overall Equipment Effectiveness (OEE) which includes three main aspects: Availability, Performance Rate, and Quality Rate. International standards set optimal values for OEE, where Availability Ratio > 90%, Performance Rate > 95%, Quality Rate > 99%, and OEE > 85.4%. The research results show that although the average Availability Ratio reaches 90.5%, the Performance Rate and Quality Rate are still below international standards. Improvements in Performance Rate and Quality Rate are needed to meet international standards and increase production efficiency. The average OEE value is 77.1%, therefore improvements are needed in the Performance Ratio and Quality Rate to meet international standards. Among the factors causing Six Big Losses, three main causes contribute to losses, namely: Equipment Failure (Breakdown Losses) of 11.7%, Process Defect Losses of 7.34%, and Reduce Yield Losses of 64.6%. Of these three main causes, reduced yield Losses have the largest impact with a percentage of 64.6%, which is caused by machine instability due to improper handling by maintenance operators. Through the application of the Failure Mode Effect and Analysis (FMEA) method, it was found that bearings that experienced cracks were the most influential cause of failure with a Risk Priority Number (RPN) value reaching 60. This problem is caused by the production operator’s lack of concern regarding machine damage, delays in reporting to maintenance officers, errors in installing spare parts, poor maintenance control, and insufficient compressor air pressure. Therefore, the main improvements that need to be made to increase the productivity of Winding machines at PT. XYZ is in the areas of Equipment Failure (Breakdown Losses), Process Defect Losses, and Reduce Yield.
ISSN:1742-6588
1742-6596
DOI:10.1088/1742-6596/2928/1/012013