Increasing Overall Equipment Effectiveness in Automotive Company Using DMAIC and FMEA Method
Ahmad Rozak, Choesnul Jaqin, Hasbullah Hasbullah
Abstract
Cylinder Block Machining Line in Indonesian automotive company has launched a worldclass company, but this company still has intention to increase the OEE value. The aim of this research was to show the application of Failure Mode and Effect Analysis (FMEA) for increasing OEE value using the DMAIC cycle (Define, Measure, Analyze, Improve and Control). Others tool to analyze this problem were Pareto Diagram and Cause and Effect Diagram. Before improvement condition, the availability average value was 90.5% from the total of production loading time. FMEA was one of tool to select the priority of the production problem that should be taken action, so it could improve the industrial operating system from the long time and frequent breakdown equipment base on highest FMEA Risk Priority Number, by additional critical components check point and feedback system to others machine for similar problem. Thus, the ITS-0015 machine that selected as observed machine could reduce the machine breakdown time from 111 became 85 minutes/month and breakdown quantity from 4.7 became 3.5 times/month. Finally, we could increase the availability value from 90.8% became 96.0% and the impact was increasing OEE value from 87% became 92%.