MAINTENANCE MANAGEMENT OF MACHINERY IN THE AUTOMOTIVE EXHAUST FILTER PRODUCTION PROCESS

Abstract

This study originated from the recurring breakdowns of the D1 Coating machine, a critical point in the automotive exhaust filter production line. Analysis of four months of historical data indicated a high breakdown rate of 9.02%, machine availability of only 88.98%, a mean time between failures (MTBF) of 2,200 minutes per failure, and a mean time to repair (MTTR) of 275 minutes per failure. These conditions caused significant losses in production time, product quality, and operational costs. The objectives of this research were: 1) to enhance the maintenance efficiency of the machinery, and 2) to systematically analyze and resolve the breakdown problems of the D1 Coating machine. The research process involved verifying the accuracy of machine stoppage records, analyzing failure trends, and applying the Seven Quality Control Tools (7 QC Tools) along with a cause-and-effect diagram to identify root causes. The findings revealed that the main causes were belt loosening and slipping from the pulley, as well as bearings that were not maintained according to the appropriate schedule, resulting in accelerated wear and increased risk of machine downtime. To address these issues, a predictive maintenance plan was developed using three time-series forecasting models: decomposition, Holt–Winters exponential smoothing, and double exponential smoothing. Model accuracy was assessed to determine the most suitable approach. After implementation, the breakdown rate decreased to 0.04%, machine availability increased to 99.98%, MTTR decreased to 10 minutes per failure, and MTBF increased to 11,505 minutes per failure, indicating a substantial improvement in machine reliability. It is recommended that the factory establish a centralized maintenance database and implement regular predictive inspection cycles to strengthen the sustainability and long-term effectiveness of the maintenance system.