Reliability Engineering Framework for Improving Manufacturing System Availability Through Failure Prevention and Performance Enhancement Strategies

Ansarullah Lawi (Institut Teknologi Batam)
Fathan Mubina Dewadi (Politeknik Negeri Jakarta)
Indriyani Indriyani (Sang Bumi Ruwa University)

Journal of Industrial Engineering and Management
Vol 1, No 4 (2023)

Manufacturing availability depends on how quickly failure-prone assets are identified, how consistently their failure data are defined, and how maintenance actions are connected to operational consequences. This study develops a descriptive reliability-engineering framework for a ten-equipment manufacturing dataset and an eight-component failure mode and effects analysis (FMEA) register. The framework integrates availability, mean time between failures (MTBF), mean time to repair (MTTR), failure rate, reported annual breakdowns, repair cost, and risk priority number (RPN). The results show a mean recorded availability of 99.02%, 117 reported annual breakdowns, and reported repair cost of IDR 495.7 million. The injection molding machine has the highest observed failure rate at 1.718 failures per 1,000 h, while the robotic welding machine has the lowest availability at 98.38%. Bearing overheating has the highest FMEA RPN of 192; hydraulic-seal leakage and gearbox wear also exceed the stated RPN 150 intervention threshold. The framework prioritizes targeted preventive actions, condition monitoring, and review of detection controls rather than claiming a causal improvement from the descriptive data. It offers a reproducible way to connect equipment records with component-level risk decisions and to monitor whether planned interventions subsequently change availability, failure exposure, and repair burden