Analisis downtime paper machine 7 menggunakan overall equipment effectiveness (OOE) dan failure mode and effects analysis (FMEA) di PT fajar surya wisesa TBK

Abstract

This study aims to analyse downtime on Paper Machine 7 at PT Fajar Surya Wisesa Tbk. using Overall Equipment Effectiveness (OEE) and Failure Mode and Effects Analysis (FMEA). Based on operational data for January?December 2025, total downtime was 137,033 minutes (2,283.88 hours), consisting of 63,569 minutes of planned downtime and 73,464 minutes of unplanned downtime.Loading Time of 462,031 minutes and Operating Time of 388,567 minutes resulted in Availabilityof 84.10%. Aggregate Performance was 98.36%, based on actual speed and ideal speed according to product basis weight, while aggregate Quality was 85.67%. Therefore, aggregate OEE for 2025 was 70.87%. Unplanned downtime was dominated by Wet End Cleaning (17,396 minutes; 23.68%), Mechanical Breakdown (14,767 minutes; 20.10%), and Dry End Cleaning (11,855 minutes; 16.14%), with a cumulative contribution of 59.92%. FMEA of five failure modes identified Mechanical Breakdown with the highest RPN of 378 (S=9, O=7, D=6), followed by Wet End Cleaning 360,Dry End Cleaning 280, Dryer Trouble 270, and Canvas Repair & Change 240. The integrated resultsindicate that reducing unplanned downtime, strengthening preventive maintenance and condition monitoring, and controlling cleaning activities are proposed improvements for Paper Machine 7.