Effectiveness Analysis of a Multiwire Drawing Machine Using Overall Equipment Effectiveness and Failure Mode and Effect Analysis

The copper wire drawing process on the Multiwire Drawing (MWD) machine must run smoothly to ensure that automotive cable production is not disrupted. However, MWD Machine 8 experienced repeated shutdowns from April through June 2026. This study aims to evaluate the machine’s effectiveness, identify major disruptions, investigate possible causes of wire breaks, and determine maintenance priorities for components. The study employed a descriptive quantitative approach based on production reports, downtime records, observations, and interviews with operators, production leaders, and supervisors. The data were analyzed sequentially using Overall Equipment Effectiveness (OEE), the Six Big Losses, Fishbone diagrams, and Failure Mode and Effects Analysis (FMEA), supplemented by a sensitivity analysis of risk values. The results showed 243 stoppage incidents, including 168 wire break incidents (69.14%). Out of 1,586 hours of planned production time, downtime totaled 245.78 hours, resulting in a combined availability of 84.50%. The frequency of wire breaks decreased from 17.50 to 8.49 incidents per 100 hours of operation between April and June. However, the final OEE value could not yet be determined because the machine’s ideal technical speed had not been verified, and the provisional performance calculation for May reached 111.40%. The FMEA identified defective dies (RPN 288), clogged dryers (280), defective contact tubes (280), and defective capstans (210) as high priorities. Sensitivity analysis showed that the priority of the first three components remained high when a single score changed by one point. The study concluded that wire breaks were the most frequent disruptions, but their contribution to total downtime duration was unknown. Consequently, the company needs to prioritize component inspections, improve the recording of disruption durations, and verify production data. These results provide a basis for developing a more targeted and measurable maintenance schedule