FAILURE MODE EFFECT ANALYSIS OF DOWNTIME IN HAWASSA MILLENNIUM PEPSI-COLA PLANT: AN IMPEDIMENT TO PRODUCTION PROCESS AND PRODUCT OUTPUT

Abstract

Every manufacturing plant faces downtime due to several reasons. The minimization of downtime may have a positive effect on the product output of a company. The main objective of this study is to analyze the effect of downtime on the production process and product output in the Hawassa Millennium Pepsi-Cola Plant. It was found out that on average the company loses 3,807,614 btl/year (38.65%) due to downtime. 6 machines and one process were selected for further investigation based on their higher downtimes. The selected machines and process collectively contributed 968.24hr (72.19%) of the downtime. Interview was used to identify 32 failure modes and 89 potential causes of the selected machines and process. The nearest probable value of downtime of each of the potential causes was determined. Pareto Analysis was used to identify failure causes that contributed 80% of downtime as a result the number of failure modes was reduced to 19 and potential causes were reduced to 29. Five-Why Analysis was used to identify the root causes of the failure causes. Failure-Mode Effect Analysis (FMEA) was used to identify severity(S), occurrence (O), and detection (D) variables additionally it was used to rank failure causes based on their RPN (risk priority number) value. The Failure Mode and Effect Analysis in the Production Room helped to rank the potential causes of failure into 13 groups whereas, in the Water Treatment Room, the potential failure causes were ranked in 3 groups. By applying preventive maintenance procedures based on the selected and ranked failure causes the researcher believes the company can improve actual production time and product output. According to the study 77.35hr (11.74 %) reduction of selected failure causes can result in the increase of actual production time by 77.35hr (2.30%) and product output by 19,473.08bottles (1.88%) per month