A Systems Engineering Approach to Increasing Machine Reliability in Automotive Battery Industry Using Quality Control Circle Methods
Year: 2026
Type: other
Abstract: Machine reliability is an important factor in the manufacturing industry, including at PT XYZ, which produces lead-acid batteries. On Line 1 of the AMB Charging Finishing Area, the Mean Time Between Failure (MTBF) value was 11.8 hours that below the company standard target 13.2 hours. This condition has resulted in increased downtime, maintenance costs, and decreased productivity. This study aims to identify the causes of low MTBF and make improvements using the Quality Control Circle (QCC). The analysis results show several main root causes, including ball screw design without bearings, corrosion-prone sensors, obsolete servo types, and poorly protected cable connections. Improvements were made by modifying the ball screw, replacing the sensors with acid-resistant ones, replacing the servo with a standard factory type, and modifying the connections to a closed junction box. The implementation of these improvements resulted in a 17% increase in MTBF to 14.30 hours, an 18.9% decrease in Mean Time To Repair (MTTR), and a 26.7% decrease in the frequency of damage. From a financial perspective, these improvements offer potential annual savings from reduced overtime and spare parts savings of IDR 228,546,880. The implementation of QCC has proven effective in improving machine reliability and is recommended for replication on other lines to maintain the sustainability of the improvements.
Author: Yulianto, Hubertus Davy
Institution: Binus University
Language: English
Subfield: Safety, Risk, Reliability and Quality
Field: Engineering
Domain: Physical Sciences
Open Access status: green
OpenAlex ID: W7140099028