Effectiveness Measurement Method

Oct 13, 2025 by vinooalluri.com 32 views

Introduction

Enno's Frame is a small and medium business (SME) that operates in the industrial field, specializing in the production of photo frame products, painting frames, and frames of frames. Despite its focus on quality products, the company faces significant challenges related to the frequent damage to its electric saw machine, which is a crucial tool in the production process. To improve the performance and effectiveness of the machine, it is essential to measure its effectiveness and analyze the causes of damage. This study aims to calculate the effectiveness of electric saws using the Overall Equipment Effectiveness (OEE) method and Failure Mode and Effect Analysis (FMEA) to provide proposed improvements.

Effectiveness Measurement Method

The OEE method is a widely used technique to evaluate the effectiveness of machine tools by considering three main factors: Availability, Performance Efficiency, and Product Quality. In this study, data was collected from July 2021 to December 2021 to analyze the effectiveness of the electric saw machine. The results of the analysis showed the average availability value of 96.14%, performance efficiency of 26.93%, and product quality level of 95.28%. From these calculations, the OEE value obtained is 24.67%, which is far below the expected standard of 85%. This indicates that the electric saw machine is not operating at its optimal level, resulting in significant losses in productivity and quality.

Causes of Low Effectiveness

The results of the analysis revealed that the low OEE value is mainly due to the low performance efficiency. A Pareto diagram was used to identify the biggest type of loss, which was found to be "reduced speed losses," accounting for 84.99% of the total losses. The main cause of this loss is frequent damage to the machine, which significantly affects operational effectiveness. To dig deeper, a cause and effect diagram was used to identify several causative factors, including:

High frequency of damage
Wear of engine components
Lack of work procedures
Lack of operator skills
High workloads

These factors contribute to the low performance efficiency of the electric saw machine, resulting in significant losses in productivity and quality.

Analysis of Failure Mode and Effect Analysis (FMEA)

FMEA analysis was carried out to identify potential risks and provide a risk priority number (RPN) value. The results of the analysis showed that the frequency of damage to the electric saw engine was the largest risk potential with a RPN value of 245. This value indicates the need for special attention and immediate improvement action to prevent further damage to the machine.

Proposed Improvement

Based on the results of the analysis, several steps can be taken to increase the effectiveness of electric saws:

Preventive Maintenance: Schedule routine checks to identify and repair damage before it occurs.
Clear Maintenance Standards: Arrange clear maintenance standards, including procedures for testing the machine after repair and ensuring that all components are well installed.
Operator Training: Provide training to improve operator skills, enabling them to handle problems that may arise during the operational process.

Conclusion

By analyzing the effectiveness of electric saws through OEE and FMEA, UKM ENNO's Frame can identify existing problems and formulate appropriate improvement steps. Increasing the effectiveness of the machine will not only have a positive impact on productivity but will also improve the quality of the product produced, which in turn can support the growth and sustainability of the business. The proposed improvements outlined in this study can help to reduce losses in productivity and quality, ultimately leading to a more efficient and effective production process.

Recommendations

Based on the findings of this study, the following recommendations are made:

Implement Preventive Maintenance: Schedule routine checks to identify and repair damage before it occurs.
Develop Clear Maintenance Standards: Arrange clear maintenance standards, including procedures for testing the machine after repair and ensuring that all components are well installed.
Provide Operator Training: Provide training to improve operator skills, enabling them to handle problems that may arise during the operational process.

By implementing these recommendations, UKM ENNO's Frame can improve the effectiveness of its electric saw machine, leading to increased productivity, improved quality, and sustained growth.

Limitations of the Study

This study has several limitations, including:

Limited Data Collection: Data was collected from a single machine, which may not be representative of the entire production process.
Limited Analysis: The analysis was limited to the OEE and FMEA methods, which may not capture all the factors affecting the effectiveness of the machine.
Limited Recommendations: The recommendations outlined in this study are based on the findings of this study and may not be applicable to all production processes.

Future Research Directions

Future research directions include:

Extending the Analysis: Extending the analysis to include other factors that may affect the effectiveness of the machine, such as equipment design and maintenance practices.
Comparing Methods: Comparing the effectiveness of different methods, such as OEE and FMEA, to identify the most effective approach.
Implementing Recommendations: Implementing the recommendations outlined in this study and evaluating their effectiveness in improving the production process.

By addressing these limitations and exploring new research directions, future studies can build on the findings of this study and provide a more comprehensive understanding of the effectiveness of electric saw machines in UKM ENNO's Frame.

Q: What is the Overall Equipment Effectiveness (OEE) method?

A: The OEE method is a widely used technique to evaluate the effectiveness of machine tools by considering three main factors: Availability, Performance Efficiency, and Product Quality.

Q: What are the three main factors considered in the OEE method?

A: The three main factors considered in the OEE method are:

Availability: The percentage of time the machine is available for production.
Performance Efficiency: The percentage of time the machine is operating at its optimal level.
Product Quality: The percentage of products produced that meet the required quality standards.

Q: What is the expected standard for OEE?

A: The expected standard for OEE is 85%.

Q: What is the OEE value obtained in this study?

A: The OEE value obtained in this study is 24.67%, which is far below the expected standard of 85%.

Q: What are the main causes of low OEE value?

A: The main causes of low OEE value are:

High frequency of damage
Wear of engine components
Lack of work procedures
Lack of operator skills
High workloads

Q: What is the Pareto diagram?

A: The Pareto diagram is a tool used to identify the biggest type of loss, which in this case is "reduced speed losses," accounting for 84.99% of the total losses.

Q: What is the risk priority number (RPN) value?

A: The RPN value is a measure of the risk potential of a particular failure mode, with higher values indicating a higher risk.

Q: What is the RPN value obtained in this study?

A: The RPN value obtained in this study is 245, indicating a high risk potential.

Q: What are the proposed improvements to increase the effectiveness of electric saws?

A: The proposed improvements are:

Preventive Maintenance: Schedule routine checks to identify and repair damage before it occurs.
Clear Maintenance Standards: Arrange clear maintenance standards, including procedures for testing the machine after repair and ensuring that all components are well installed.
Operator Training: Provide training to improve operator skills, enabling them to handle problems that may arise during the operational process.

Q: What are the limitations of this study?

A: The limitations of this study are:

Limited Data Collection: Data was collected from a single machine, which may not be representative of the entire production process.
Limited Analysis: The analysis was limited to the OEE and FMEA methods, which may not capture all the factors affecting the effectiveness of the machine.
Limited Recommendations: The recommendations outlined in this study are based on the findings of this study and may not be applicable to all production processes.

Q: What are the future research directions?

A: The future research directions include:

Extending the Analysis: Extending the analysis to include other factors that may affect the effectiveness of the machine, such as equipment design and maintenance practices.
Comparing Methods: Comparing the effectiveness of different methods, such as OEE and FMEA, to identify the most effective approach.
Implementing Recommendations: Implementing the recommendations outlined in this study and evaluating their effectiveness in improving the production process.