Application of Failure Mode and Effect Analysis (FMEA) for Functional Failure Analysis of a Reach Stacker: A Case Study at a Container Terminal Service Company

Abstract

Logistics and cargo handling activities at ports require reliable equipment to maintain operational efficiency. One of the primary handling machines used in container terminals is the reach stacker, which functions to lift and move containers. However, the high intensity of operation frequently causes component failures that interrupt loading and unloading activities. This study aimed to identify critical components and dominant failure causes in reach stacker unit number 73 operating at a container terminal company. Historical breakdown and utilization data from 2021–2023 were analyzed using the Failure Mode and Effect Analysis (FMEA) method. A Functional Block Diagram (FBD) was first developed to describe the relationship among system components and to support the identification of functional failures. The FMEA method was then applied by evaluating severity, occurrence, and detection parameters to obtain the Risk Priority Number (RPN) of each failure mode. The results indicate that the spreader subsystem has the highest risk level, particularly the failure mode of a jammed or unresponsive twist-lock mechanism during lock/unlock operation, with an RPN value of 360. Other high-risk components include the brake system, chassis, hydraulic system, air conditioning, horn, and wiring system. The findings show that most failures are associated with low detectability and intensive operating conditions. Therefore, maintenance activities should prioritize the spreader and other safety-related components through risk-based maintenance and predictive inspection strategies.