Failure Analysis of Main Components of Crimping Machines Using the FMEA Method

Abstract

The reliability of crimping machines is essential to maintain production quality and operational continuity in the wire harness manufacturing industry. This research analyzes failures in the UniCrimp 208 Crimping Machine using the Failure Mode and the Effects Analysis (FMEA) method to identify critical components and determine improvement actions. Data were collected through observation, interviews, and documentation. The results showed that the crimping die, cutter blade, and Feeding mechanisms were the main contributors to machine downtime and production interruptions. The FMEA analysis indicated that the crimping die had the highest Risk Priority Number (RPN) value of 360, followed by the Cutter Blade with 280 and the Feeding Mechanism with 210. Pareto analysis confirmed that These components contributed to most machine failures. Root Cause Analysis identified component wear, inadequate preventive maintenance, improper machine setup, and operator error as the main causes of failure. Several Improvement actions were implemented, including preventive maintenance, scheduled maintenance, SOP improvement, operator training, and spare parts management. After improvement, the RPN values significantly decreased, with the The crimping die was reduced to 108, the cutter blade to 72, and the feeding mechanism to 63. The results demonstrate that the proposed improvements effectively reduced machine failure risks, minimized downtime, and improved machine reliability. Keywords: FMEA, crimping machine, maintenance, RPN, machine failure.