Track: Lean Six Sigma Competition

Abstract

In industrial applications, specifically in the manufacturing sector, it is essential to know the machine's status. Most companies have advanced machines; however, the data regarding the machine's condition are not highly considered resulting in many problems like low productivity and high rejection rate that constitute cost and environmental impact. This study aims to assess the die casting injection machines of a leading automobile manufacturing company in Indonesia that can be used for manufacturing companies experiencing the same difficulties. Twenty aluminum alloy die casting injection machines were studied in this research. The machine breakdown was summarized, and it turned out that machine 16 was the most problematic among the machines. The results show an Overall Equipment Effectiveness (OEE) of 40.95%. The idling and minor stoppages and breakdown loss was the main contributor to the problem having the abnormal die lock an RPN of 392, with severity (7), occurrence (7), and detection (8) as the leading cause based on the Failure Mode and Effect Analysis (FMEA) results. The findings will provide automobile manufacturing companies and other related industries comprehensive information on properly assessing productivity problems. Therefore, the results can give relevant perspectives on proper procedures integrating productivity analysis in the manufacturing process.