Overall Equipment Effectiveness (OEE) analysis and Failure Mode and Effect Analysis (FMEA) on Packer Machines for minimizing the Six Big Losses - A cement industry case

Abstract

Bosowa Maros Cement Company (BMC) is a company engaged in the production of cement. There are seven packer machines for the packaging process to fulfill the demand in BMC. The most problems are many breakdowns that occur on packer machines, and the amount of production, which not maximum, causes a lack of Overall Equipment Effectiveness (OEE) value. The research aimed to identify the performance of packers based on production data using OEE and Failure Mode Effect Analysis values. The results of the six big losses and the Pareto diagram show that the most affect losses in causing the low achievement of OEE values on both machines are reduced speed loss, idling and minor stoppages, equipment failure (breakdown loss) for Packer 3 is 94.27% and Packer 7 is 90.41%. The average OEE value of the Packer 3 machine is 53%, and the Packer 7 machine is 36%. OEE values on the two machines have not reached the OEE ideal standard by the Japan Institute of Plant Maintenance (JIPM), which is 85%.