Integrated HOR RCA Framework Prioritizes Preventive Maintenance for Circular Knitting Machines

Abstract

General Background: Machine reliability is essential for maintaining continuous production in the textile industry, particularly where repeated equipment failures generate downtime and operational constraints. Specific Background: PT MNJ experiences frequent disruptions in circular knitting operations, while maintenance activities have not been systematically scheduled. Knowledge Gap: Research integrating risk prioritization with root cause investigation and structured mitigation for circular knitting operations remains limited. Aims: This study identifies and addresses major disruption risks through House of Risk (HOR) Phase 1, Root Cause Analysis (RCA), and HOR Phase 2 using interview data, expert questionnaires, and historical machine-failure records. Results: Eighteen risk agents were identified, of which 10 dominant agents accounted for 79.70% of total Aggregate Risk Potential. The absence of a systematic preventive maintenance and cleaning schedule was the dominant factor with an ARP of 1,113. Routine daily-to-monthly maintenance scheduling through a Standard Operating Procedure obtained the highest Effectiveness to Difficulty Ratio of 3,339. Novelty: The study combines HOR and RCA to establish a quantitative, root-cause-oriented risk management approach for textile production equipment. Implications: The integrated procedure provides an operational reference for prioritizing mitigation actions, controlling recurrent equipment failures, reducing downtime, and improving production efficiency. Highlights: Eighteen risk agents were detected, with ten accounting for 79.70% of total risk potential. Lack of systematic servicing and cleaning recorded the highest ARP value of 1,113. Daily-to-monthly scheduling through an SOP achieved the highest ETDk value of 3,339. Keywords: Risk Management, House of Risk, Root Cause Analysis, Circular Knitting, Risk Mitigation