Rising Downtime Pressures Across Manufacturing
Industrial production lines increasingly depend on uninterrupted machine operation. In sectors like ceramics, where firing and drying processes rely on high-temperature equipment, mechanical failure can disrupt entire production cycles.
The case examined by Nasrulloh and Marlapa illustrates this challenge clearly. Repeated machine stoppages not only slowed production but also raised maintenance costs, delayed shipments, and weakened operational stability. The study positions maintenance management as a strategic factor in industrial competitiveness rather than a purely technical issue.
Research Design and Data Sources
The study combines quantitative performance measurement with qualitative operational analysis.
Researchers evaluated maintenance logs, production reports, and cost records from January 2022 to December 2024. They focused on two machines that had the greatest operational impact: a roller kiln and a tunnel oven.
The analysis used three integrated steps:
- Measuring machine performance through Overall Equipment Effectiveness (OEE), which combines availability, speed, and product quality.
- Investigating failure causes through interviews, group discussions, and structured diagnostic mapping.
- Designing corrective strategies using systematic planning tools to connect problems with actionable solutions.
This method allowed the researchers to link numerical performance indicators with organizational decision-making.
Major Findings: From World-Class to Critical Performance
The data reveal a steep drop in equipment effectiveness across the three-year observation period:
- 2022: OEE stood at 90.32 percent, reflecting highly efficient operations.
- 2023: OEE fell to 76.95 percent, indicating growing inefficiencies.
- 2024: OEE dropped sharply to 42.75 percent, signaling severe operational breakdown.
The decline resulted from simultaneous decreases in machine availability, slower processing speed, and reduced product quality.
Instead of isolated mechanical faults, the research uncovered a systemic pattern of recurring failures linked to management practices.
What Actually Caused the Decline
The study identifies five interconnected drivers behind the performance drop:
- Insufficient technician training and weak knowledge transfer systems
- Aging machines forced to operate beyond recommended capacity
- Maintenance procedures focused on repair after failure instead of prevention
- Limited spare-part stock and inconsistent component quality
- Budget reductions that delayed upgrades and maintenance investments
Nasrulloh and Marlapa argue that financial decision-making played the central role. Cost-cutting policies reduced spare-part availability and delayed equipment renewal, which in turn increased repair frequency and downtime.
According to the authors, short-term budget savings ultimately produced larger operational losses, highlighting the need for a long-term reliability strategy.
Pathways to Recovery
The research outlines a recovery framework designed to restore machine reliability and stabilize production performance. Key actions include:
- Establishing minimum inventory levels for critical spare parts
- Strengthening technician certification and technical training programs
- Replacing or overhauling essential machine components before failure occurs
- Introducing routine inspection tasks for production operators
- Presenting maintenance funding as a productivity investment rather than an expense
Based on simulation modeling, implementing these strategies could raise equipment effectiveness to approximately 79 percent, bringing operations back to a stable industrial standard.
Broader Implications for Industry
The study reinforces a growing consensus in industrial management: maintenance strategy is directly tied to productivity, supply reliability, and financial performance.
Factories that reduce maintenance spending often face escalating downtime, declining product quality, and rising hidden costs. By contrast, organizations that prioritize equipment reliability and workforce skills can improve efficiency while protecting long-term competitiveness.
For policymakers and industrial planners, the research highlights how stable maintenance systems support national manufacturing resilience and supply chain continuity.
Insight from the Researchers
Nasrulloh, a researcher in industrial operations management at Universitas Mercu Buana, notes that machine failures often reflect organizational decisions rather than technical limitations. Marlapa, also from Universitas Mercu Buana, emphasizes that maintenance spending should be treated as a strategic investment that safeguards productivity and asset value.
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