Identification of Critical Machine in Textile Industry Using Reliability‐Centred Maintenance and Failure Mode and Effects Analysis—A Case Study of Bahir Dar Textile's Share Company

ABSTRACT Reliability‐Centred Maintenance (RCM) is an economical maintenance approach that places more emphasis on sustaining system functionality than just fixing individual hardware parts. Failure Mode and Effects Analysis (FMEA), one of the main techniques in RCM, is used to determine possible failure modes, their underlying causes, and how they affect system performance. This study identifies the greatest risk that affects the system by using a higher risk priority number (RPN) and clearly illustrates the maintenance plan for each failure scenario. By putting in place a systematic RCM policy, the study seeks to reduce these risks. The results show that, in terms of the impact of failure, the machines in the spinning portion are the most crucial. By lowering risk through a focused FMEA approach, the RCM methodology's implementation shows notable economic benefits. The suggested approach improves maintenance efficiency by concentrating on the most important 20% of failure causes. According to the findings, implementing RCM resulted in a 31.5% decrease in labour expenses. Additionally, compared to the case company Bahir Dar Textile Share Company's (BDTSC) present run‐to‐failure maintenance policy, the proposed maintenance plan reduced the yearly spare parts costs by 28.12%. The results highlight RCM's potential for enhancing maintenance plans, cutting expenses, and raising overall operational effectiveness in the textile industry.