Failure Tree Analysis of CNC Plasma Cutting Machine for Occupational Safety on Shipyard

Mochamad Yusuf Santoso; Aulia Nadia Rachmat; Amalia Rahma Fauzia

doi:10.12962/j25481479.v9i2.20261

Failure Tree Analysis of CNC Plasma Cutting Machine for Occupational Safety on Shipyard

Mochamad Yusuf Santoso, Aulia Nadia Rachmat, Amalia Rahma Fauzia

Abstract

The advancement of ship production technology in Indonesia involves the implementation of modern techniques integrating computer-based design and production facilities, such as Computer-Aided Manufacturing (CAM) for operating production machines utilizing Computer Numerical Control (CNC). One specific type of CNC machine utilized in ship production is the plasma cutting CNC machine. Despite being crucial to production, these machines frequently encounter failures that impede the production process. Through prior failure analyses conducted by the company, it has been identified that the dust collector air hose component exhibits the highest failure rate with six distinct failure modes. This article conducts qualitative and quantitative analyses of the causes of failure in the air hose dust collector of CNC plasma cutting machines using the Fault Tree Analysis (FTA) method. FTA is employed as a method to ascertain the fundamental causes of the event. The analysis results are utilized to provide recommendations for controlling objectives related to occupational safety. Six failure trees are generated, comprising a total of 28 basic causes. The most frequently occurring types of basic causes are associated with workers, methods, and materials. The probability of occurrence for the minimal cut set of each failure tree has been successfully computed. These calculations reveal that all top events possess probability values exceeding 76%. Specifically, the event of the dust collector air gap breaking has the highest probability value, reaching 99.88%, which is a composite of 15 basic causes. Control recommendations are provided in the form of substitution, engineering solutions, and administrative controls.

Keywords

CNC Machine; Failure Cause; Fault Tree Analysis; Safety; Shipbuilding

Full Text:

PDF

References

Ministry of Industry of the Republic of Indonesia. (2022, September 20). Shipyard Production Capacity Increases, Ministry of Industry Supplies Reliable Human Resources. Press conference. https://kemenperin.go.id/article/23551/Kapasitas-Proksi-Galangan-Kapal-Meningkat,-Kemenperin-Pasok-SDM-Andal

Bachtiar, AI, Marimin, M., Adrianto, L., & Bura, RO (2021). Strategy for Increasing Industrial Competitiveness Shipping (Shipbuilding Industry). Journal Application Business And Management, 7 (1), 121-134.

Hasbullah, M. (2016). Strategy for Strengthening National Shipyards in Order to Strengthen the Effectiveness and Efficiency of the National Domestic Shipping Fleet 2030. Journal of Research and Technology Oceanography (JRTK), 14 (1), 103-112.

Ma'ruf, B. (2014). National Ship Industry Development Strategy Based on Domestic Production and Markets. Agency for the Assessment and Application of Technology Press.

[Irfan, S., & Rusiyanto, R. (2021). CNC Plasma Cutting Design Using Autodesk Inventor 2015 Software. Journal of Mechanical Engineering, 12(1), 1. https://doi.org/10.21776/ub.jrm.2021.012.011

Maysarah, AP, Atmaji, FTD, & Alhilman, J. (2019). Planning Remote Monitoring Simulation with Vibration Sensor For Predicting Damage CNC Milling Machine A at PT. Sandy Globalindo. EProceedings of Engineering, 7130-7136.

Arif, R., Juniani, AI, & Indrawan, R. (2018). Determining Maintenance Intervals for Critical Components of the CNC Flame Plasma Cutting Machine using the Reliability Centreed Maintenance (RCM) Method. Proceedings Conference on Design Manufacturing Engineering and Its Applications, 183-188.

Dickenson, M. W. (2020). Plasma Cutting Machine Explosion. https://www.edtengineers.com/blog-post/plasma-cutting-machine-explosion

Gu, D., Zhong, Y., Xu, Z., Chen, B., & Wang, Z. (2022). An importance measure of a CNC lathe considering failure correlations. Quality and Reliability Engineering International, 38(3), 1367-1379. https://doi.org/10.1002/qre.2963

Banjarnahor, HS (2021). Factors Analysis Of Failure And Reliability Of Electric Functions In Steel Production Processes Using FMEA, FTA, RCA And RBD At PT. Growth Sumatra Industry Medan-North Sumatra. Journal of Basic Science and Technology, 10 (1), 32-41.

[Whiteley, M., Dunnett, S., & Jackson, L. (2016). Failure Mode and Effect Analysis, and Fault Tree Analysis of Polymer Electrolyte Membrane Fuel Cells. International Journal of Hydrogen Energy, 41(2), 1187-1202. https://doi.org/10.1016/j.ijhydene.2015.11.007

Nurwulan, NR, & Veronica, WA (2020). Implementation of Failure Mode and Effect Analysis and Fault Tree Analysis in Paper Mill: A Case research. Journal of Industrial Systems Engineering, 9 (3), 171-176. https://doi.org/10.26593/jrsi.v9i3.4059.171-176

Ruijters, E., & Stoelinga, M. (2015). Fault tree analysis: A survey of the state-of-the-art in modelling, analysis and tools. Computer Science Review, 15-16, 29-62. https://doi.org/10.1016/j.cosrev.2015.03.001

Ghivaris, G. Al, Soemadi, K., & Desrianty, A. (2015). Suggestions for Improving the Quality of the Rudder Tiller Production Process at PT PINDAD Bandung Using FMEA and FTA. National Institute of Technology Online Journal, 3 (4), 73-84.

Sriwindiarto, H. (2023). Analysis of Machining Jig Design of Base Crankshaft Pulley Puller on CNC Milling Machine with FMEA and FTA Methods at PT. XYZ. G-Tech: Journal of Applied Technology, 7(4), 1653-1662.

Rahman, R., Nursanti, E., & Soemanto. (2023). Application of Overall Equipment Effectiveness (OEE) and Fault Tree Analysis (FTA) methods in Measure Effectiveness of DMG Mori CNC Machine in the Bogie Machining Process at PT Barata Indonesia (Persero). Journal Valtech (Journal Industrial Engineering Student), 6 (1), 93-102.

Kang, J., Sun, L., & Guedes Soares, C. (2019). Fault Tree Analysis of floating offshore wind turbines. Renewable Energy, 133, 1455-1467. https://doi.org/10.1016/j.renene.2018.08.097

Anggani, F., Widiana, D.R., Rachmat, A.N. (2023). Hazard Identification of Iron and Steel Smelting Process with Kupola Kitchen Using Fault Tree Analysis Method. Conference on Safety Engineering and It's Application

International Organisation for Standardisation. (2018). Occupational Health and Safety Management Systems. In ISO 45001:2018. International Organisation for Standardisation.

Li, Y., Zhang, X., Ran, Y., & Zhang, G. (2021). Early failure modelling and analysis of CNC machine tools. The International Journal of Advanced Manufacturing Technology, 112 (9-10), 2731-2754. https://doi.org/10.1007/s00170-020-06495-0

Rabani, H.A., Dirja, I., & Fauji, N. (2022). Analysis of Gemini Ficep G25 SP CNC Machine Damage Using the Failure Mode Effect Analysis (FMEA) Method. ROTOR: Scientific Journal of Mechanical Engineering, 15 (1), 26-31.

DOI: http://dx.doi.org/10.12962/j25481479.v9i2.20261