Total Productive Maintenance Analysis Using OEE and FMEA Method at PT. XYZ Phosphoric Acid Factory

Abstract

The smooth production process in the company is influenced by several factors, one of which is the machine. Machine maintenance is something that needs to be done by the company because it has an important role in the smooth production process. PT XYZ is a company engaged in the manufacture of fertilizers and chemicals. Phosphoric Acid Plant, production department III A, PT XYZ, in its production process, has 193 machines that are used to process phosphate rock. Based on a survey related to problems that often occur at the Phosphoric Acid Plant, it can be seen that three machines have the highest breakdown time, namely 1st Filter (Fil-2321), 1st Vacuum Pump (C-2323), and Digester (R-2302 B). From these problems, machine maintenance analysis was carried out using Total Productive Maintenance with Overall Equipment Effectiveness and Failure Mode Effect and Analysis methods.

Defect Analysis Using Fault Tree Analysis and Failure Mode Effect Analysis in Rubber Roll Production

“…Data processing and analysis techniques are performed using the Fault Tree Analysis (FTA) method to identify the main event or top event; create a fault tree and determine the cut-set from the fault tree analysis (Relkar, 2021). Meanwhile, the Failure Mode and Effect Analysis (FMEA) method is used to identify potential failure modes in the production process (Saifuddin et al, 2022); identify potential failure effects in the production process; identify potential causes of failure in the production process; determine severity, occurrence, and detection rating values based on their respective rating indicators; and calculate the Risk Priority Number (RPN) using the formula Risk Priority Number (RPN) = S × O × D (Hidayat & Kholil, 2018). The analysis in this research results in proposed improvements for the three main factors causing product defects with the highest RPN values, which have been sorted during data processing.…”