Analysis of Machine Maintenance Processes by using FMEA Method in the Sugar Industry

Abstract

Sugar is the daily basic need of human life. It is made from cane trees and manufactured using a milling machine in the early stages. This machine is operated 24 hours per day; consequently, it should be in a good condition and the company must be able to ensure the machine can run well by scheduling regular maintenance. This study aimed to investigate the potential failure of manufacturing process to provide some recommendations for improvement. Failure Mode and Effect Analysis (FMEA) method was applied to analyze the situation, and Logic Tree Analysis (LTA) was implemented to classify the types of improvement. This study found 13 failure modes, including a loose hammer tip, a broken end of the cutter, a non-balanced hammer rotation, a broken hammer handlebar, a broken wheel bearing, a loose switch, a loose split pen, a loose fastener bolt, an overload, a destroyed rubber seal, a broken turbine coupling, a broken screw-bolt, and a hollow roller. Meanwhile, the classification of improvement consisted of 3 categories namely safety problem (A), outage problem (B), and economic problem (C). Subsequently, the A category recommended setting up the machine in accordance with SOP while the B category recommended inspecting the machine routinely and preparing parts. In addition, the C category recommended performing accurate installation, lubrication, and cleaning.