IMPROVEMENT OF MACHINERY MAINTENANCE EFFICIENCY IN PRODUCTION: A CASE STUDY OF BEVERAGE FACTORY

Abstract

This study is to research the problem of optimizing machine maintenance in the production process, case study of a beverage factory from the 2019 production plan. There are plans for the production of a total of 3,243 hours, which encounter problems of machinery defects throughout the year, total 907 hours, or 27.96 percent. The film pack machine has found a problem of the failed cutting film. Applying, engineering management is to analyze the problem and root cause with Pareto diagram and cause and effect diagram respectively. It is found that the factory lacks an effective maintenance management system with a maintenance plan is not related with the current machine operation. Therefore, this study has proposed the Proactive Maintenance system including of Predictive Maintenance and Preventive Maintenance for modify existing maintenance

The results show that the average monthly loss time of the breakdown film packer is decreased by 29.45%, the machine availability rate for the entire production process is increased by 73.44% to 85.77%, the efficiency of the machine performance is increased by 90.69 to 96.88%. The quality rate is increased by 99.65% to 99.85%. Finally, the Overall Equipment Effectiveness (OEE) is increaed by 66.36% to 82.97% with the difference of increasing approximately 16.6%