Analysis Of The Effectiveness Of Mixer Spiral Using The Overall Equipment Effectiveness (OEE) Method And Failure Mode And Effect Analysis (FMEA) At PT. Sehati Tortilla

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Analysis of the Effectiveness of Mixer Spiral Using the Overall Equipment Effectiveness (OEE) method and Failure Mode and Effect Analysis (FMEA) at PT. Sehati Tortilla

Introduction

In the production of tortillas, PT. Sehati Tortilla, a company that specializes in producing kebab leather, has a target of 1,500 packs of tortillas every day. To achieve this target, production machines, including spiral mixers, must always be in optimal conditions. However, the spiral mixer, which is tasked with stirring flour, water, and other ingredients to become a uniform dough, is often damaged. This has the potential to inhibit the production process and reduce overall efficiency. Therefore, it is essential to analyze the effectiveness of the spiral mixer using the Overall Equipment Effectiveness (OEE) method and Failure Mode and Effect Analysis (FMEA) to identify areas for improvement.

Background

PT. Sehati Tortilla is a company that produces tortillas, and its production process involves the use of spiral mixers to stir flour, water, and other ingredients to become a uniform dough. The spiral mixer is a critical machine in the production process, and its effectiveness is crucial to achieving the company's production targets. However, the spiral mixer is often damaged, which can lead to downtime and reduce overall efficiency.

Methodology

To analyze the effectiveness of the spiral mixer, this study used the Overall Equipment Effectiveness (OEE) method and Failure Mode and Effect Analysis (FMEA). The OEE method is a widely used method for evaluating the effectiveness of equipment, and it takes into account three key factors: availability, performance efficiency, and quality rate. The FMEA method is a systematic approach to identifying and evaluating potential failures in a system or process.

Results

The results of the OEE analysis showed that during the period June 2023 to February 2024, the Spiral Mixer had an average level of availability of 89.06%. The main factor that affects the availability is the breakdown loss (loss due to damage) of 8.93%. The performance efficiency (performance efficiency) reaches 86%, with the dominant factor being the reduced speed loss (loss due to a decrease in speed) of 10.75%. Meanwhile, the rate of quality has reached 100%.

Analysis of Results

The analysis shows that Reduced Speed Loss has the most significant impact on the effectiveness of spiral mixers. The average OEE value only reached 72.46%, far below the ideal standard of 85%. This indicates that the spiral mixer is not operating at its optimal level, and there is a need to improve its effectiveness.

Cause and Effect Diagram (Ishikawa Diagram)

A Cause and Effect Diagram (Ishikawa Diagram) was used to identify the factors that cause reduced speed loss. The diagram shows that several factors contribute to reduced speed loss, including machine, human, methods, and the environment.

FMEA Analysis

The FMEA analysis shows that the frequency of spiral mixer damage has a RPN value (risk priority number) of 336, which is relatively high (> 300). The main factor causing damage is the wear of the gearbox.

Recommendations

To minimize damage and increase the effectiveness of the spiral mixer, some improvements need to be taken, namely:

  • Apply a cooling break for 15 minutes when a spiral mixer is used for a long time.
  • Perform routine lubrication every 2-4 weeks.

Conclusion

Increasing the effectiveness of spiral mixers through these steps will have a positive impact on the production performance of PT. Sehati Tortilla. By reducing downtime and increasing production speed, companies can achieve their production targets optimally and increase competitiveness in the market.

Future Research Directions

Future research directions include:

  • Conducting a more in-depth analysis of the factors that contribute to reduced speed loss.
  • Developing a more effective maintenance schedule for the spiral mixer.
  • Implementing a quality control system to ensure that the spiral mixer is operating at its optimal level.

Limitations of the Study

The study has several limitations, including:

  • The study only analyzed the effectiveness of the spiral mixer during a specific period.
  • The study did not take into account other factors that may contribute to reduced speed loss.
  • The study did not develop a comprehensive maintenance schedule for the spiral mixer.

Recommendations for Future Studies

Future studies should:

  • Conduct a more comprehensive analysis of the factors that contribute to reduced speed loss.
  • Develop a more effective maintenance schedule for the spiral mixer.
  • Implement a quality control system to ensure that the spiral mixer is operating at its optimal level.

Conclusion

In conclusion, this study analyzed the effectiveness of the spiral mixer using the Overall Equipment Effectiveness (OEE) method and Failure Mode and Effect Analysis (FMEA) at PT. Sehati Tortilla. The results showed that the spiral mixer has a low level of effectiveness, and several factors contribute to reduced speed loss. The study recommends implementing a cooling break and routine lubrication to minimize damage and increase the effectiveness of the spiral mixer. Future research directions include conducting a more in-depth analysis of the factors that contribute to reduced speed loss and developing a more effective maintenance schedule for the spiral mixer.
Q&A: Analysis of the Effectiveness of Mixer Spiral Using the Overall Equipment Effectiveness (OEE) method and Failure Mode and Effect Analysis (FMEA) at PT. Sehati Tortilla

Q: What is the Overall Equipment Effectiveness (OEE) method?

A: The Overall Equipment Effectiveness (OEE) method is a widely used method for evaluating the effectiveness of equipment. It takes into account three key factors: availability, performance efficiency, and quality rate.

Q: What is the purpose of using the OEE method in this study?

A: The purpose of using the OEE method in this study is to analyze the effectiveness of the spiral mixer at PT. Sehati Tortilla and identify areas for improvement.

Q: What are the three key factors that the OEE method takes into account?

A: The three key factors that the OEE method takes into account are:

  1. Availability: This refers to the percentage of time that the equipment is available for use.
  2. Performance Efficiency: This refers to the percentage of time that the equipment is operating at its optimal level.
  3. Quality Rate: This refers to the percentage of time that the equipment is producing high-quality products.

Q: What is the main factor that affects the availability of the spiral mixer?

A: The main factor that affects the availability of the spiral mixer is the breakdown loss (loss due to damage) of 8.93%.

Q: What is the dominant factor that affects the performance efficiency of the spiral mixer?

A: The dominant factor that affects the performance efficiency of the spiral mixer is the reduced speed loss (loss due to a decrease in speed) of 10.75%.

Q: What is the rate of quality of the spiral mixer?

A: The rate of quality of the spiral mixer is 100%.

Q: What is the average OEE value of the spiral mixer?

A: The average OEE value of the spiral mixer is 72.46%, which is far below the ideal standard of 85%.

Q: What is the main factor causing damage to the spiral mixer?

A: The main factor causing damage to the spiral mixer is the wear of the gearbox.

Q: What are the recommendations for improving the effectiveness of the spiral mixer?

A: The recommendations for improving the effectiveness of the spiral mixer are:

  • Apply a cooling break for 15 minutes when a spiral mixer is used for a long time.
  • Perform routine lubrication every 2-4 weeks.

Q: What are the future research directions for this study?

A: The future research directions for this study include:

  • Conducting a more in-depth analysis of the factors that contribute to reduced speed loss.
  • Developing a more effective maintenance schedule for the spiral mixer.
  • Implementing a quality control system to ensure that the spiral mixer is operating at its optimal level.

Q: What are the limitations of this study?

A: The limitations of this study include:

  • The study only analyzed the effectiveness of the spiral mixer during a specific period.
  • The study did not take into account other factors that may contribute to reduced speed loss.
  • The study did not develop a comprehensive maintenance schedule for the spiral mixer.

Q: What are the recommendations for future studies?

A: The recommendations for future studies include:

  • Conducting a more comprehensive analysis of the factors that contribute to reduced speed loss.
  • Developing a more effective maintenance schedule for the spiral mixer.
  • Implementing a quality control system to ensure that the spiral mixer is operating at its optimal level.