Enhancing APTV Reliability: A Study of Design and Operational Efficiencies at An Aluminium Manufacturing Company

This paper aims to focus on enhancing the reliability of Anode Pallet Transport Vehicles (APTVs) used in Aluminium Manufacturing Company. The primary objective of the project is to establish the causes of failure modes, assess the operational problems, and implement strategies that would prevent, reduce, or minimize the frequency of failure, low equipment utilization, and high maintenance costs. APTV performance analysis involves the use of maintenance logs, operational data, and engineering specifications to obtain the best results. Applying Failure Mode and Effects Analysis (FMEA), the study highlights the most critical parts causing the largest effect on operations, which include traction motors, leaf springs, and tires. Moreover, unlike conventional brainstorming methods, tools such as RCA Fishbone, and 5 Whys are integrated to identify deep-rooted problems spanning organizational, mechanical, and environmental systems. The project also takes a closer look into the efficiency of the fleet with time utilization and cycle time analysis, where time gap can be identified. The study indicates that design changes, proactive maintenance, and other related management activities are effective ways of improving vehicle reliability. The project identifies the potential failure modes and provides a specific set of engineering solutions to reduce risk while providing guidelines on the frequency of maintenance. Overall, this report offers realistic solutions that would help enhance the reliability and operational effectiveness of APTV fleet across Aluminium Manufacturing Company, whether in the short term or for the long-term strategy formulating.