2nd International Conference Eco-Innovation in Science, Engineering, and Technology

Volume 2021
http://dx.doi.org/10.11594/nstp.2021.1449

Conference Paper

Production Machine Effectiveness Analysis Using Overall Equipment

Effectiveness (OEE) and Root Cause Analysis

Joumil Aidil Saifuddin*, Isna Nugraha, Yekti Condro Winursito

Department of Industrial Engineering, Universitas Pembangunan Nasional “Veteran” Jawa Timur, Surabaya
60294, Indonesia

*Corresponding author: ABSTRACT

E-mail:
[email protected]
A manufacturing company in production activities requires machinery and
equipment. The machine has reliability, namely the opportunity for the machine to
operate according to its function in a certain period. Company XYZ is a company
located in Sidoarjo and is engaged in manufacturing with the main product being
White Crystal Sugar (GKP). Company XYZ has several machines or equipment that
operate 24 hours throughout the milling season with a series and parallel system so
that the probability of damage to machine components is quite high. One of the
machines that are often damaged is the boiler engine. Based on the problems that
exist in this company, it is necessary to evaluate the engine performance at the boiler
station during the milling period. The methods used in this research are Overall
Equipment Effectiveness (OEE) and Root Cause Analysis. The OEE value obtained by
the machine at the boiler station at Company XYZ for machines that have a value
above the ideal standard of 85%, namely bagasse carrier IV, bagasse carrier III,
bagasse carrier II, belt conveyor, reclaimer I, and reclaimer II. Meanwhile for
machines that have a value below the ideal standard of 85%, namely boilers KCC of
77.98%, boilers FCB of 81.73%, and bagasse carrier I of 82.37%. This condition
shows that production is considered reasonable, but still shows that there is a large
room for the company to make developments.

Keywords: Overall equipment effectiveness, six big losses, root cause analysis.

Introduction
A manufacturing company in production activities requires machinery and equipment. To
maintain a smooth production process, the company must use production facilities properly and
make periodic repairs (Xiang & Feng, 2021). The machine has reliability, namely the opportunity
for the machine to operate according to its function in a certain period. This can be maintained by
performing good maintenance activities on the machine.
Company XYZ is a company located in Sidoarjo and is engaged in manufacturing with the main
product being White Crystal Sugar (GKP). Company XYZ has 7 stations consisting of milling
stations, boiler stations, purification stations, evaporation stations, cooking stations, spin stations,
and finishing stations. Company XYZ has several machines or equipment that operate 24 hours
throughout the milling season with a series and parallel system so that the probability of damage
to machine components is quite high. One of the machines that are often damaged is the boiler
engine.
Based on the problems that exist in this company, it is necessary to evaluate the engine
performance at the boiler station during the milling period. The methods used in this research are
Overall Equipment Effectiveness (OEE) and Root Cause Analysis. With the proper care and
maintenance system, it is expected to increase the company's productivity (Hamali et al., 2021).

How to cite:
Saifuddin, J. A., Nugraha, I., & Winursito, Y. C. (2021). Production machine effectiveness analysis using Overall
Equipment Effec-tiveness (OEE) and root cause analysis. 2nd International Conference Eco-Innovation in Science,
Engineering, and Technology. NST Proceedings. pages 320-328. doi: 10.11594/ nstp.2021.1449
 2nd ICESET 2021

Literature Review
Maintenance
Maintenance is an activity carried out to maintain or improve work facilities to create the
conditions desired by the company (Arsyad & Sultan, 2018). Maintenance needs to be taken to
keep machines and production equipment from damage and machine failure in a company.
Activities in this maintenance are carried out by repairing, disassembling, and checking the
machine as a whole. The flow of the maintenance can be seen in Figure 1.

Figure 1. Maintenance function in the industry

From the picture above, it can be seen that maintenance is very necessary for the production
process. A good production process will certainly produce products with good quality,
competitive prices, and on time.

Overall Equipment Effectiveness (OEE)

OEE is a comprehensive measure that identifies the level of productivity of
machines/equipment and their performance (Chikwendu et el., 2020). OEE is expressed as an
output ratio. This measurement is very important to find out which areas need to be increased
productivity or machine effectiveness and can also show bottleneck areas in the production line.
OEE is also a measuring tool to evaluate and improve the right way to ensure increased
productivity in the use of machines/equipment. There are three main measurement ratios in OEE,
namely: Availability Rate (AR), performance rate (PR), and rate of quality (RQ) (Saiful et al., 2014).
Six big losses are categorized in OEE (Chikwendu et el., 2020). The OEE model can be seen in
Figure 2.

Figure 2. Overall Equipment Effectiveness factors

In calculating the OEE value, it is necessary to calculate the availability rate, performance rate,
and rate of quality (Nallusamy et al., 2018). Availability Rate (AR) is the willingness of machines
to operate or use the equipment. The amount of the availability rate is calculated by the formula
can be seen in the following equation:

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AR = 𝑥 100% (1)

Performance rate (PR) is the effectiveness of production activities. The amount of

performance rate is calculated by the formula:

PR = 𝑥 100% (2)

The rate of quality (RQ) is the effectiveness of production based on the quality of the resulting
product (ƞ quality). The rate Of Quality can be calculated by the following equation:

RQ = 𝑥 100% (3)

After obtaining the value of availability rate, performance rate, and rate of quality, then the
OEE calculation is carried out using the equation:

OEE % = Availability rate x Performance rate x Rate of Quality (4)

Root Cause Analysis (RCA)

Root cause analysis is a tool used to identify the causes of a problem. There are several
tools used in RCA, one of which is the fishbone diagram or Ishikawa diagram because it was
proposed by Kaoru Ishikawa in 1960 who is an expert in quality management from Japan
(Toklu et al, 2016). Fishbone diagrams are used in discussion forums using the brainstorming
method to identify why a problem occurs (Al-Zwainy et al, 2018). This diagram illustrates the
factors that cause a problem written in detail as shown in Figure 3.

Figure 3. Fishbone Diagram

Material and Methods

This research was conducted at company XYZ which is engaged in manufacturing with the
main product being white crystal sugar located in Sidoarjo. The method used in this research is
Overall Equipment Effectiveness (OEE) which is used to calculate efficiency and Root Cause
Analysis to analyze the system and find failures in the boiler engine. The data used in this research
are machine data, running time, planned downtime, downtime, set up, stop time, breakdown,
processes amount, and defects amount. The results of data processing in this study are expected
to be able to provide recommendations for improvement in boiler engine maintenance. The steps
taken in this research were to determine the critical station that experienced the highest
downtime during the milling period and then calculate the engine effectiveness value at the boiler
station using the Overall Equipment Effectiveness (OEE) method. After obtaining the OEE value,

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then calculate the six big losses to find out one of the factors that most influence the OEE value.
The last step is to identify machine failures using the Root Cause Analysis method.

Result and Discussion

Data Collection
Researchers collect data and information from companies to solve problems. The data needed
include machine data at the boiler station, machine running time, planned machine downtime,
machine downtime, machine setup time, machine breakdown, machine stop time, total
production, and defect amount.

Table 1. Company machine data collection

Total Total Total Total
Total Defect
Running Planned Total Break Stop Total
No Machine Productio Amount
Time Downtim Set-Up down Time Downtim
n (Ton) (Ton)
(Hour) e (Hour) (Hour) (Hour) (Hour) e (Hour)

1 Bagasse Carrier I 60506.91 0 2836.5 300.25 33.99 35.12 130.46 199.57

Bagasse Carrier
2 80506.91 0
II 2958.5 240.25 10.76 3.97 125.46 140.19

Bagasse Carrier
3 80506.91 0
III 2958.5 240.25 8.61 0 125.46 134.07

Bagasse Carrier
4 80506.91 0
IV 2958.5 240.25 16.43 46.49 125.46 188.38

5 Belt Conveyor 3336 0 2958.5 240.25 7.11 0 125.46 132.57

6 Reclaimer I 3336 0 2958.5 240.25 7.11 0 125.46 132.57

7 Reclaimer II 3336 0 2958.5 240.25 7.11 0 125.46 132.57

8 Boiler FCB 38585.46 0 2786.5 240.25 95.41 37.7 135.46 268.57

9 Boiler KCC 38585.46 0 2903.5 240.25 108.25 180.76 110 399.01

Source: Data processing

Calculation of the Overall Equipment Effectiveness (OEE) and Six Big Losses Machine
Data processing is carried out using the Overall Equipment Effectiveness (OEE) method
which is based on three factors, namely availability, performance efficiency, and quality rate
(Rusman et al., 2019). Availability calculation describes the utilization of machine time at the
boiler station available to carry out operations (Jaqin et al., 2020), Performance rate describes the
actual ability of the machine to operate at an ideal speed based on capacity, and the quality rate is
carried out using data on the amount of bagasse that was successfully processed and the amount
that was not successfully processed.

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Table 2. Calculation of availability, performance efficiency and quality rate of machines

Defect Performance Quality
Loadin Operatio Total Ideal Cycle
Amount Availability Efficiency Rate
No Machine g Time n Time Productio Time
(%) (%)
(Hour) (Hour) n (Ton) (Hour/Ton)
(Ton) (%)

1 Bagasse Carrier I 2536.25 2336.68 60506.91 0.0345 0 92.131 89.414 100

2 Bagasse Carrier II 2718.25 2578.06 80506.91 0.0294 0 94.842 91.879 100

3 Bagasse Carrier III 2718.25 2584.18 80506.91 0.0295 0 95.067 91.879 100

4 Bagasse Carrier IV 2718.25 2529.87 80506.91 0.0289 0 93.069 91.879 100

5 Belt Conveyor 2718.25 2585.68 3336 0.7121 0 95.122 91.879 100

6 Reclaimer I 2718.25 2585.68 3336 0.7121 0 95.122 91.879 100

7 Reclaimer II 2718.25 2585.68 3336 0.7121 0 95.122 91.879 100

8 Boiler FCB 2546.25 2277.68 38585.46 0.0539 0 89.452 91.378 100

9 Boiler KCC 2663.25 2264.24 38585.46 0.0538 0 85.017 91.725 100

Source: Data processing

After obtaining the value of availability, performance efficiency, and quality rate, the
measurement of the OEE value can be carried out on each machine at the boiler station. The results
of the OEE calculation can be seen in Table 3.

Table 3. Calculation of Machine OEE at Boiler Stations and OEE Classification According to JIPM
Calculation Results
Standard
Factor of Ba-
World Bagasse Bagasse Bagasse Belt Re-
OEE Boiler Boiler gasse Re-
Class Carrier Carrier Carrier Con- claimer
KCC FCB Carrier claimer I
IV II III veyor II
I

Availability 90% 85.01% 89.45% 92.13% 93.06% 94.84% 95.06% 91.87% 95.12% 95.12%

Performance
95% 91.72% 91.37% 89.41% 91.87% 91.87% 91.87% 91.87% 91.87% 91.87%
Efficiency

Quality Rate 99% 100% 100% 100% 100% 100% 100% 100% 100% 100%

100%

OEE 85% 85.51% 87.14% 87.34% 87.39% 87.39% 87.39%

OEE 60% 77.98% 81.73% 82.37%

40%

Source: Data processing

From Table 3 above, it can be seen that the calculation of the engine OEE value at the boiler
station for those that have a value above the ideal value of 85% include bagasse carrier II, bagasse
carrier III, bagasse carrier IV, belt conveyor, reclaimer I, and reclaimer II. Meanwhile, those that
have not reached the ideal value of 85% are bagasse carrier I of 82.37%, boilers FCB of 81.73%,
and boilers KCC of 77.98% which according to the OEE Classification in Japan Institute of Plan
Maintenance this value is included in the normal category, production is considered reasonable
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but still shows there is a large room for the company to develop, and the company's
competitiveness is reduced.
The second stage after getting the OEE value from each machine at the boiler station is to
measure the six big losses. Six big losses are six factors that affect the OEE value. The value of six
big losses for each machine at the boiler station that is not ideal is calculated to determine the
most dominant and influential factors on the OEE value, namely bagasse carrier I, boilers FCB, and
boilers KCC. Six big losses are represented by downtime losses (breakdown losses, set up, and
adjustment losses), speed losses (idling and minor stoppages losses and reduced speed losses),
and defect losses (rework losses and scrap losses) (Dewi et al., 2020).

Table 4. Calculation of the machine six big losses factors at the boiler station
Boiler KCC Boiler FCB Bagasse Carrier
No Six Big Losses I
Percentage Percentage
(%) (%) Percentage (%)

1 Breakdown Losses 6.787 1.480 1.384

2 Set Up & Adjustment Losses 4.064 3.747 1.340

Idle and Minor Stoppages

3 13.151 14.755 16.982
Losses

4 Reduced Speed Losses 7.034 7.712 9.752

5 Rework Losses 0 0 0

6 Scrap Losses 0 0 0

Total 832.48 791.51 700.8

Source: Data processing

From the calculation of the percentage of the six big losses factor above, the highest factor
percentage for the bagasse carrier I machine is Idling and Minor Stoppages Losses of 16.98%, for
the machine boilers FCB are Idling and Minor Stoppages Losses of 14.75%, and for boilers, KCC is
Idling and Minor Stoppages Losses of 13.15%.

Root cause analysis

To find out the problems that affect the effectiveness of the machines at the boiler station, it
is described in the Root Cause Analysis. The benefit of Root Cause Analysis is that it shows cause-
and-effect relations or factors that affect the level of efficiency by doing brainstorming. The
influencing factors are man, method, materials, machine, and environment (Nurmutia et al., 2020).

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Figure 4. Root Cause Analysis of Boiler KCC Machine

Figure 5. Root Cause Analysis of Boiler FCB Machine

Figure 6. Root Cause Analysis of Bagasse Carrier I Machine

From the results of the Root Cause Analysis, recommendations are made to reduce the value
of idling and minor stoppages losses and reduce speed losses in boilers KCC, boilers FCB, and
bagasse carrier I to increase engine effectiveness at boiler stations:
1. Man:
a. Provide direction and education about the importance of following the existing SOP rules to
increase the sense of responsibility in each operator.

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b. Conducting briefings before changing shifts to provide preventive direction, and checking
machines to reduce the possibility of machine damage and shift changes being carried out
on the production floor.
2. Method:
a. Provide regular and scheduled maintenance training.
b. Lubrication and cleaning standards are established and created spare parts inventory pol-
icy.
3. Materials
a. Further improving the supervision of the bagasse because not all bagasse is milled perfectly
so that if there is a lump of bagasse it needs to be followed up so that the bagasse doesn't
stick together in the bagasse feeder and other equipment that accidentally gets into the
bagasse.
4. Machine
a. Regular engine checks are carried out to reduce the rate of sudden engine damage and can
prepare for component replacement quickly.
b. The technician needs to redesign the scrapper, it is hoped that with shorter dimensions it
is not too tight against the barrier and is not easily impacted by the movement of the chain
so that the scraper does not bend quickly.
5. Environment
a. Keeping the work environment clean.
b. Checking the cleanliness of equipment such as chains and pipes as well as the cleanliness
of the operator's place so that supervision can be maximized.

Conclusions
Based on data processing and analysis of the results that have been carried out, it can be
concluded that:
1. The OEE value obtained by the machine at the boiler station at Company XYZ for machines
that have a value above the ideal standard of 85%, namely bagasse carrier IV, bagasse
carrier III, bagasse carrier II, belt conveyor, reclaimer I, and reclaimer II. This condition
shows that production is categorized as world-class because it can be used as a long-term
goal and has very good competitiveness. Meanwhile for machines that have a value below
the ideal standard of 85%, namely boilers KCC of 77.98%, boilers FCB of 81.73%, and
bagasse carrier I of 82.37%. This condition shows that production is considered
reasonable, but still shows that there is a large room for the company to make
developments. The availability value is between 85.01-95.12%, performance efficiency is
between 89.41-91.87%, and the machine quality rate is 100%. The highest level of
machine effectiveness at the boiler station based on the OEE method was 87.39% obtained
by the Belt Conveyor, Reclaimer I, and Reclaimer II machines. And the lowest effectiveness
is the boiler KCC 77.98%.
2. The dominant factor influencing the low OEE value of 3 machines (bagasse carrier I, boiler
FCB, and boiler KCC) at the boiler station so that it does not meet the ideal standard value
is factor idling and minor stoppages losses with values between 13.15-16.98% and
reduced speed losses with a value between 7.03-9.75%.

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