Volume 6, Issue 8, August – 2021 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Performance Measurement Analysis of Injection

Molding Machine JSW J450AD Using Methods
Overall Effectiveness (OEE) And Failure Mode
Effect Analysis ( FMEA ) In The Plastics Industry
Iwan Saputro, Erry Rimawan, Alib Sabaruddin, Wahyu Abadi
Mercu Buana University

Abstract:- PT. Bumimulia Indah Lestari is a Keywords:- Injection Molding, Downtime, OEE, Reduced
manufacturing company that produces plastic packaging Speed Losses, Equipment Failure Losses, FMEA,
using injection molding machines. The problem faced by Improvement.
the company is the high downtime of the JSW J450AD
machine. during the early semester of 2020, the total I. INTRODUCTION
downtime of the machine was 18,060 hours. From these
problems, the author tries to measure machine Nowadays, there is a very rapid growth in the use of
performance using the Overall Equipment Effectiveness plastic products because they are very versatile and have
method. OEE measurement results show an average of high economic value. The Aromatile, Olefin, and Plastic
72.35%. Based on the Pareto diagram analysis, the Industry Association (Inaplas) predict that the national
biggest causes of the low OEE number are reduced speed plastic industry will still grow 7% this year.
losses by 14%. After an analysis using FMEA, it was
found that mold overheating was the biggest cause of PT. Bumimulia Indah Lestari is a manufacturing
failure with RPN 448. The recommendation for company engaged in the manufacture of plastic packaging
improvement given was to carry out routine inspections such as bottles, caps, jerrycans, pallets. The problem faced
of the cooling system such as checking the condition of by the company is the high downtime of the JSW J450AD
the hose, compressor chiller air pressure, and the injection molding machine at plant 2. The following is the
condition of the nozzle. machine downtime data for the period from January 2020 to
June 2020.

Table.1 Downtime Machine JSW J450AD

Changeover Mould Breakdown Mould Cleaning Total
Month Downtime
(minute) (minute) (minute) (minute)
January 2020 960 2.790 270 4.020
February 2020 720 2.412 108 3.240
March 2020 582 1.782 156 2.520
April 2020 600 1.386 174 2.160
Mei 2020 840 2.568 312 3.720
June 2020 708 1.470 222 2.400
Total 4.410 12.708 1.242 18.060
( Source : Internal company data )

Based on table above, the total downtime data for the Various efforts such as repairs (maintenance) have been
JSW J450 AD injection molding machine was very high carried out by the company but the actual number of
during the period from January 2020 to June 2020, reaching downtime is still very high. From these problems the author
18,060 minutes and the highest downtime occurred in tries to provide a solution so that downtime can be reduced,
January 2020, which was 4,020 minutes. Downtime is one of namely by measuring machine performance with the Overall
the factors that affect the optimization of production machines Equipment Effectiveness method. Measuring machine
(Prabowo & R, 2019). The effect of high downtime is a performance is very important so that we can find out how
decrease in the speed and performance of the effectively the machine is used.
machine/equipment so that the output produced is not
optimal and in the end will reduce the level of productivity.

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Volume 6, Issue 8, August – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
II. LITERATURE REVIEW 1.3 Failure Mode Effect Analisys
FMEA was first used in 1940 by the United States
Maintenance is all activities that are important with the military and began to be developed as a methodology for the
aim of producing a good product or to restore it to a aerospace and defense industry in 1960. Until now the
satisfactory state. Maintenance can be defined as an activity FMEA method has been used as a tool to analyze potential
needed to maintain or maintain the quality of maintenance failures that occur in the production process in industry.
of a facility so that the facility can function properly in a
ready-to-use condition (Sudrajat, 2011). Failure Mode and Effects Analysis (FMEA) is one of
the failure analysis methods applied in product
1.1 Types of Maintenance development, system engineering and operational
Up to now, there are three types of maintenance, management. FMEA is carried out to analyze potential
namely planned maintenance, unplanned maintenance and errors or failures in the system or process, and the identified
autonomous maintenance. potentials will be classified according to the magnitude of the
potential failure and its effect on the process. In eliminating
1.1.1 Planned Maintenance these potential problems, it is necessary to do an assessment
Planned maintenance is maintenance that is organized first by calculating the Risk Priority Number (RPN). To
and carried out with future thinking, control and recording calculate the RPN value, we must first know the scores from
according to a predetermined plan. According to (Corder, the categories of impact (severity), frequency (occurance),
Antony, K. Hadi, 1992) Planned maintenance is divided into and detection (detection). The formula to get the RPN value
two main activities, namely preventive maintenance and is as follows:
corrective maintenance. RPN = Severity x Occurance x Detection
Information :
 Preventive Maintenance Severity = Impact arising from failure Occurance = The rate
Preventive maintenance is a periodic inspection to of occurrence of failure Detection = Ability to possibly
detect conditions that might cause production to stop or detect failure
reduce the function of the machine combined with Risk Priority Number (RPN) = Risk value obtained from the
maintenance to eliminate, control, these conditions and multiplication of severity, occurrence, and detection
return the machine to its original condition or in other words
self-detection and treatment of abnormal machine conditions III. RESEARCH METHOD
before the condition. it causes damage or loss.
In this research, the writer uses descriptive quantitative
 Corrective Maintenance research method/type. Quantitative research is a process of
According to Corder, Antony, K. Hadi, (1992), finding knowledge that uses data in the form of numbers as a
corrective maintenance is maintenance that is carried out tool to analyze information about what you want to know.
repeatedly or maintenance carried out to repair a part This study uses a descriptive approach with the aim of
(including adjustment and repair) that has stopped to meet describing the object and the results of the study. According
an acceptable condition. to Sugiyono (2013), the descriptive method has a function to
describe or describe the object under study through the data
1.1.2 Unplanned Maintenance or samples that have been collected. This study uses the
There is only one form of unplanned maintenance, Total Productive Maintenance (TPM) method with the
namely emergency maintenance (emergency/breakdown calculation of Overall Equipment Effectiveness (OEE). The
maintenance). Corder, Antony and K. Hadi (1992) define purpose of this research is to find out how the current
maintenance as requiring immediate action to prevent condition of machine maintenance is, whether it is optimal
serious consequences, such as loss of production, major or needs improvement.
damage to equipment, or for work safety.
To facilitate the discussion in this study, the authors
1.1.3 Autonomous Maintenance use the following framework:
Autonomous maintenance is an activity to increase
productivity and efficiency of machines/equipment through
activities carried out by operators to maintain the
machines/equipment they handle themselves.

1.2 Overall Equipment Effectiveness

According to Nakajima (1988), OEE is a method that
measures the level of effectiveness in the use of a
machine/equipment or system by taking into account several
points of view in the measurement process. OEE measures
the overall effectiveness of the equipment by multiplying
availability, performance, and quality.
Figure 1. Framework of Research Source : Authors

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Volume 6, Issue 8, August – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
IV. RESULT AND DUSCUSSION Table.2 Performace Rate
Operatio Operatio Cycle Total
 Availability Month n Time n Time Time Produc Performanc
Availability is a ratio that shows the time available to ( menit ) ( minute ( t ( shot e
operate the machine. ) secon ) (% )
d)
Availability = January 28.380 1.702.800 21 71.040 87,76
2020
When : February 33.120 1.987.200 21 84.298 89,08
2020
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒 March202 25.220 1.513.200 21 60.230 83,59
0
𝐿𝑜𝑎𝑑𝑖𝑛𝑔 𝑇𝑖𝑚𝑒 x 100% April2020 20.940 1.256.400 21 48.012 80,25
May 2020 9.600 576.000 21 18.053 65,81
Loading Time = Availability Time - Planned
Downtime Operation Time = Loading Time – Downtime June2020 33.660 2.019.600 21 90.208 93,80
Average 83,38
Table.1 Availability Rate
Operation Loading Time Source : data processing
Month Time ( menit ) Availability
( menit ) (%) Quality
According to Nakajima (1988) Quality Rate is the ratio
of the number of good products (good products) to the all
January 2020 28.380 32.400 87,60 products processed.
February 2020 33.120 36.360 91,09
Quality Rate =
March 2020 25.220 27.740 90,92
April 2020 20.940 23.100 90,65 𝐺𝑜𝑜𝑑 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 (𝑝𝑐𝑠)
Mai 2020 9.600 13.320 72,07
𝐴𝑙𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑒𝑑 (𝑝𝑐𝑠) x 100%
June 2020 33.660 36.060 93,34
Average 87,61 Table.3 Quality Rate
source : data processing Good
Month Product Reject Total Quality
Performance ( pcs ) Product Product (%)
The performance rate indicates the machine's ability to ( pcs ) ( pcs )
produce a product over a given period of time. The data
January 3.354.338 55.582 3.409.920 98,37
needed to calculate the performance rate are monthly
2020
operation time data, monthly production data, and ideal
February 4.007.459 38.845 4.046.304 99,04
cycle time for 1 unit of product. In this study the author uses
2020
a cycle time that has been set by the company, which is 21
seconds. March 2.878.320 12.720 2.891.040 99,56
2020
Performance Rate = April 2020 2.285.449 19.127 2.304.576 99,17
May2020 794.315 72.085 866.400 91,68
𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒 𝑥 Total
Produksi x 100% June 2020 4.293.090 36.894 4.329.894 99,15
Average 97,82
The following is the result of calculating the
performance of the JSW J450AD engine for a period of 6 Source : data processing
months:
Overall Equipment Effectiveness
After obtaining the availability, performance and
quality values for each month, the Overall Equipment
Effectiveness (OEE) is calculated with the following
formula:

OEE (%) = Availability x Performance x Quality

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Volume 6, Issue 8, August – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table.4 Result of OEE Calculating Table.5 Recapitulation of the results of the calculation of
losses
Month Availability Performance Quality OEE Equipment Setup & Idling Reduced Rework
(%) (%) (%) (%) Month Failure Adjustment And Speed Losses
January 87,60 87,76 98,37 75,62 Losses Losses Minor Losses (%)
2020 (%) (%) Stopages (%)
February 91,09 89,08 99,04 80,36 (%)
2020 January 2,96 8,6 0,83 10,85 0,34
March2020 90,92 83,59 99,56 75,67 2020
April2020 90,65 80,25 99,17 72,14 February 1,98 6,6 0,29 9,94 0,19
May2020 72,07 65,81 91,68 43,48 2020
June2020 93,34 93,80 99,15 86,80 March2020 2,09 6,4 0,56 14,92 0,24
Average 72,35 April2020 2,6 6 0,75 17,90 0,32
Source : data processing May2020 6,3 19,28 2,3 24,64 0,80
June2020 1,93 4,08 0,61 5,79 0,20
Based on the results of the OEE calculation in table 4
Average 8,49 2,98 0,89 14,00 0,35
above, it is known that the average result shows the number
72.35%. This figure is still below the world-class OEE Source : data processing
standard, namely ≥85%. So there needs to be improvement
to the machine. Table.6 Dominant causative factor
Average Persentage Cumulative
Six Big Losses Analysis Type of losses (%) (%) Percentage
After knowing that the OEE results are below the (%)
standard, the next step is to analyze losses using a Pareto Equipment Failure 8,49 31,8 31,8
diagram. The purpose of this analysis is to determine the Set up & Adjustment 2,98 11,2 43
factors of the six big losses that have the most influence on Idling & Minor Stopages 0,89 3,3 46,3
the low OEE results. Reduced Speed 14.00 52,4 98,7
Rework 0,35 1,3 100
Total 26,71 100
Source : data processing

Figure.2 Pareto Losses Diagram for January 2020 to June 2020 Source : data processing

From the Pareto diagram above, it can be seen that the The next step is to find the cause of the reduced speed
most dominant loss factor that causes low OEE is reduced on the JSW J450AD machine with a fishbone diagram and
speed with an average of 14%. root cause failure analysis (RCFA).

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Volume 6, Issue 8, August – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table.7 RCFA Causative Reduced Speed of JSW J450AD Machine
Factor No Why Why Why Why Why
Operator lacks of Have not receiving Busy of production Customer request
1 Knowledge training schedule
Man
Operate more than one Efficiency man
2 Human Error tired machine power
The machine often has a Electrical short circuit Less preventive High of production Customer request
1 breakdown often occurs maintenance loading
Mold Overheating Chiller circulation is Compressor air pressure Leaky hose Lack of regular
2 not optimal is low checks

Lack of
regular
3 Swing arm Gear worn Lack of checking
stuck lubrication of
lubricating
oil
Lack of
Machine checking
4 Screw Barrel is not Bearing worn Lack of lubrication lubricating oil
center regularly

Need long time for Parts Spare part stock Spare part usage is not Spare part stock
5 replacement machine is often empty recorded control tool Not yet made
part

Ralery cleaned WI about 5R machine is

6 Dirty Machine regularly not available Not yet created

Material Raw material room dirty

Material 1 Lumpy material contaminated with Rarely 5R No WI
water, dust, dirt

Work equipment is not Damaged or Work equipment

Long set up process Work is not sequentia completed borrowed by other is not recorded
Method 1 colleagues properly

Source : Authors

 Man : Lack of knowledge causes the ability to overcome  Material : Poor material quality because the material is
production problems to be not optimal. In addition, high lumpy. clumping material is caused because it is
production targets require operators to operate more than contaminated with water, dust and dirt, it is caused by
one machine, causing operators to be tired at work. the dirty dirty material storage room because 5R is rarely
 Machine : machine conditions that often experience done.
breakdowns due to engine damage or part failures such as  the set up process takes a long time due to incomplete
mold overheating, swing arm stuck, screw barrels are not work equipment, this happens because there is no good
in the center resulting in machine downtime so that data collection on the work equipment used.
production time is reduced. engine breakdown caused by
lack of periodic checks. In addition, the unavailability of After analyzing the causes of reduced speed using
spare parts stock results in the process of replacing spare RCFA, the next step is to find the risk priority number using
parts when there is damage or during preventive FMEA tools. After knowing the RPN of each failure mode,
maintenance to be long. the highest RPN will be selected to be the priority for
improvement.

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Volume 6, Issue 8, August – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table.8 RPN calculation results with FMEA
Failure Factor Cause of failure Effect of Failure S O D RPN
Mode
Operator Problem solving ability in the field is
Man lacks of not optimal 6 5 7 210
Knowledge
Man Human Wrong machine parameter setting 7 6 7 294
Error
The Machine stops production so output is
Machine machine reduced 8 6 8 384
often has a
breakdown
Machine Mold The product sticks to the cavity 8 7 8 448
Overheating
Reduced Speed Loss

Swing arm stuck The autoclose mechanism does not work so

Machine the product cannot be pushed out 6 5 6 180
Screw Plasticizing is not perfect
Machine Barrel is not So that the raw material is rough 8 5 6 240
center
Need long
time for
Machine replacement Machine stops operating 7 5 5 175
machine
part
Machine Dirty Decreased production quality 7 5 7 245
machine
Material Lumpy The platicizing process takes a long 6 5 5 150
Material time
Methode Proses set Reduced production time 8 7 6 336
up lama
Source : data processing

Based on the calculation of the RPN in table 8 above, it is known that the cause of the highest failure is in the machine factor,
namely mold overheating with RPN 448. Therefore, the mold overheating problem will be a priority for improvement. The tools
used by the author to recommend improvements are 5W+1H .

Table.9 Proposed Improvements to Overcome Mold Overheating

Cusative Root of What Where When Why Who How
Factor Problem
Machine Doing On JSW At the So that the production Make an
routine J450 beginning chiller operator examination
checks on AD of every circulation form/sheet
the injection shift can be
condition injection maximized
of the hose, molding so that the
chiller machine mold
compressor temperature
air is stable
pressure,
nepple
condition
Source : Authors

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Volume 6, Issue 8, August – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
V. CONCLUSION AND SUGGESTION Applications, 10(2), 43–48.
https://doi.org/10.21512/comtech.v10i2.5692
 Conclusion [6]. Prabowo, H. A., & R, D. I. (2019). Improve the Work
Based on the results of the discussion, data collection Effectiveness With OEE (Overall Equipment
and processing that has been carried out by the author, the Effectiveness) As the Basis for Optimizing Production.
following conclusions can be drawn: Pasti, IX(3), 286– 299.
1. The average amount of Overall Equipment Effectiveness [7]. Rimawan, E., & Raif, A. (2016). Analisis Pengukuran
(OEE) achievement for the JSW J450AD injection Nilai Overall Equipment Effectiveness (OEE) Pada
molding machine during the period January 2020 to June Proses Packaging Di Line 2. Sinergi, 20(2), 140–148.
2020 is 72.35%. This value is still below the OEE [8]. Rizkia, I., Adianto, H., & Yuniati, Y. (2015).
standard from JIPM (Japan Institute of Plant Penerapan Metode Overall Equipment Effectiveness
Maintenance) namely 85% so that the performance of (OEE) dan Failure Mode and Effect Analysis (FMEA)
the machine is not optimal. dalam Mengukur Kinerja Mesin Produksi Winding Nt-
2. Based on the analysis of Pareto diagram calculations, it 880N untuk Meminimasi Six Big Losses. Reka
is known that the dominant factor affecting the low OEE Integra, 3(4), 273–284.
of the JSW J450AD injection molding machine is the [9]. Sunaryo, S., & Nugroho, E. A. (2015). KALKULASI
reduced speed loss of 14%. These losses cause the OVERALL EQUIPMENT EFFECTIVENESS (OEE)
engine speed to decrease from the standard, thereby UNTUK MENGETAHUI EFEKTIVITAS MESIN
reducing the OEE. [10]. KOMATZU 80T (Studi Kasus pada PT. Yogya Presisi
3. The results of the OEE measurement show that the Tehnikatama Industri). Teknoin, 21(4), 225–233.
results are below the standard so it can be concluded that https://doi.org/10.20885/teknoin.vol21.iss4.art8
the JSW J450AD injection molding machine needs [11]. Umar Nisbantoro, F., Jinan, R., & Hardi Purba, H.
improvement. as for the proposed improvement to (2018). Measurement Overall Equipment Effectiveness
increase the effectiveness of the JSW J450AD injection on Injection Moulding Machine: A Case Study in
machine is to make a form / sheet for checking the Injection Moulding Manufacturing Industry.
condition of the hose, chiller compressor air pressure, International Journal of Engineering Research and
nepple condition. Advanced Technology, 4(8), 62–69.
https://doi.org/10.31695/ijerat.2018.3302
 Suggestion [12]. Vijayakumar, S. R., & S. Gajendran. (2014).
1. It is hoped that further research can examine OEE on Improvement of Overall Equipment Effectiveness In a
the I-57 injection molding machine so that the Plastic Injection Moulding Industry. IOSR Journal of
effectiveness of the machine increases. Mechanical and Civil Engineering (IOSR-JMCE,
2278–1684.
2. Make sure the operator and maintenance are always
consistent in checking the condition of the machine
according to the company SOP so that the machine's
reliability is maintained.

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