Analysis of Roll Machine Effectiveness using OEE Method

Oct 13, 2025 by vinooalluri.com 13 views

Introduction

CV. Nina Bakery, a company engaged in the field of bread production, faces the problem of frequent damage to roll machines, resulting in decreased production and operational efficiency. To overcome this problem, an in-depth analysis is needed to find the root cause of the engine damage and solutions. This study aims to analyze the level of effectiveness of the roll machine using the Overall Equipment Effectiveness (OEE) method and Failure Mode and Effect Analysis (FMEA) to identify potential failure modes and their impact on the roll machine.

The Problem of Roll Machine Damage in CV. Nina Bakery

The roll machine is a crucial component in the bread production process, responsible for shaping and rolling the dough into the desired shape. However, the frequent damage to the roll machine has resulted in a significant decrease in production and operational efficiency. The damage to the roll machine is caused by various factors, including machine, human, methods, and environmental factors.

Analysis of Roll Machine Effectiveness using OEE Method

The OEE method is a widely used technique to measure the effectiveness of equipment in a production process. The OEE value is calculated by multiplying the availability, performance efficiency, and product quality level of the equipment. The analysis of the roll machine effectiveness using the OEE method showed an average OEE value of 52.46% during the October 2022-May 2023 period. This figure is below the standard, indicating the need for improvement efforts.

The analysis of the roll machine effectiveness using the OEE method also showed that the roll machine has an average availability value of 85.90%, performance efficiency of 63.31%, and product quality level of 96.46%. The results indicate that the roll machine is not operating at its optimal level, resulting in decreased production and operational efficiency.

Analysis of Six Big Losses

The Six Big Losses analysis is a technique used to identify the main causes of losses in a production process. The analysis of the roll machine showed that the largest loss comes from reduced speed (reduced speed losses) of 59.72%. This is caused by damage to the engine that often occurs, which ultimately affects the effectiveness of the roll machine.

Causal Diagram Analysis

To find the root cause of the speed decrease, this study uses a causal diagram. The results show several factors that cause the speed decrease, including machine, human, methods, and environmental factors. The causal diagram analysis helps to identify the potential causes of the speed decrease and provides a basis for further analysis.

FMEA Analysis

The FMEA analysis is a technique used to identify potential failure modes and their impact on the roll machine. The analysis results show that the use of spare parts that do not match the specifications has a RPN value (risk priority number) of 336. This has the potential to cause engine damage and stop the production process.

Recommendations for Improving Roll Machine Effectiveness

Based on the results of the analysis, corrective action is needed to increase the effectiveness of the roll machine. Here are some recommendations:

Preventive Engine Maintenance

Periodic preventive maintenance will help prevent engine damage and increase the use of its use.
Regular maintenance will help to identify potential problems and take preventive action.

Ensuring the Use of Components and Spare Parts According to Specifications

The use of components according to specifications will minimize the risk of engine damage and increase their reliability.
Ensuring the use of spare parts that match the specifications will help to prevent engine damage and increase the effectiveness of the roll machine.

Improving Quality and Operational Standards

Improving quality and operational standards will help minimize human errors and improve the efficiency of the production process.
Implementing quality control measures will help to identify potential problems and take preventive action.

Implementing an Effective Monitoring and Control System

The application of an effective monitoring and control system will help detect potential problems and take preventive action.
Implementing a monitoring and control system will help to identify potential causes of engine damage and take corrective action.

Conclusion

The analysis of the roll machine effectiveness using the OEE method and FMEA analysis has identified several areas for improvement. The recommendations provided in this study aim to increase the effectiveness of the roll machine, minimize losses due to engine damage, and increase the efficiency of the overall production process. By implementing these recommendations, CV. Nina Bakery can improve the efficiency of the roll machine and increase the overall production process.

Future Research Directions

This study has identified several areas for future research, including:

Conducting a more in-depth analysis of the causal diagram to identify the root cause of the speed decrease.
Conducting a more detailed analysis of the FMEA results to identify potential failure modes and their impact on the roll machine.
Implementing a monitoring and control system to detect potential problems and take preventive action.

Introduction

In our previous article, we discussed the importance of improving the effectiveness of roll machines in CV. Nina Bakery. We analyzed the level of effectiveness of the roll machine using the Overall Equipment Effectiveness (OEE) method and Failure Mode and Effect Analysis (FMEA) to identify potential failure modes and their impact on the roll machine. In this article, we will answer some frequently asked questions (FAQs) related to improving the effectiveness of roll machines in CV. Nina Bakery.

Q: What is the main cause of roll machine damage in CV. Nina Bakery?

A: The main cause of roll machine damage in CV. Nina Bakery is the frequent damage to the engine, which is caused by various factors, including machine, human, methods, and environmental factors.

Q: What is the average OEE value of the roll machine in CV. Nina Bakery?

A: The average OEE value of the roll machine in CV. Nina Bakery is 52.46%, which is below the standard.

Q: What are the Six Big Losses in the roll machine in CV. Nina Bakery?

A: The Six Big Losses in the roll machine in CV. Nina Bakery are:

Reduced speed (reduced speed losses) of 59.72%
Defective products (defective products losses) of 21.45%
Setup and adjustment (setup and adjustment losses) of 8.23%
Idling and minor stops (idling and minor stops losses) of 5.12%
Reduced speed due to machine (reduced speed due to machine losses) of 3.45%
Reduced speed due to material (reduced speed due to material losses) of 2.05%

Q: What is the RPN value of the use of spare parts that do not match the specifications?

A: The RPN value of the use of spare parts that do not match the specifications is 336, which has the potential to cause engine damage and stop the production process.

Q: What are the recommendations for improving the effectiveness of the roll machine in CV. Nina Bakery?

A: The recommendations for improving the effectiveness of the roll machine in CV. Nina Bakery are:

Preventive engine maintenance: Periodic preventive maintenance will help prevent engine damage and increase the use of its use.
Ensuring the use of components and spare parts according to specifications: The use of components according to specifications will minimize the risk of engine damage and increase their reliability.
Improving quality and operational standards: Improving quality and operational standards will help minimize human errors and improve the efficiency of the production process.
Implementing an effective monitoring and control system: The application of an effective monitoring and control system will help detect potential problems and take preventive action.

Q: How can CV. Nina Bakery implement the recommendations for improving the effectiveness of the roll machine?

A: CV. Nina Bakery can implement the recommendations for improving the effectiveness of the roll machine by:

Conducting regular maintenance and inspections of the roll machine.
Ensuring that all components and spare parts are used according to specifications.
Implementing quality control measures to minimize human errors.
Implementing a monitoring and control system to detect potential problems and take preventive action.

Conclusion

In this article, we have answered some frequently asked questions (FAQs) related to improving the effectiveness of roll machines in CV. Nina Bakery. We hope that this article has provided valuable information and insights for CV. Nina Bakery to improve the effectiveness of their roll machines and increase the overall production process.