Improving Die Casting Machine Reliability through FMEA-Based Failure Analysis and Repair Optimization

Abstract

This research focuses on enhancing the reliability of die casting machines by applying the Failure Mode and Effect Analysis (FMEA) method to detect, assess, and mitigate potential sources of failure. Through the calculation of the Risk Priority Number (RPN), the most critical failure modes can be prioritized, forming the foundation for developing more accurate and effective corrective strategies. Data for this study was gathered through field observations, discussions with maintenance technicians, and evaluation of historical machine failure records. Findings indicate that the use of FMEA successfully highlighted the three most influential failure modes affecting machine performance, and after implementing the recommended improvements, machine uptime increased significantly with a 35% reduction in breakdown occurrences. The study confirms that combining FMEA with a systematic improvement approach can strengthen machine reliability and contribute to a more consistent and efficient production flow. Die casting is utilized due to its high production speed, cost efficiency, and suitability for manufacturing aluminum automotive components with excellent dimensional precision, ultimately reducing failures and maintenance expenses