Authors :
Ari Ramdhani; Mohammad Hilman Maulana; Rahmad Hidayat Nasution; Yudi Prastyo
Volume/Issue :
Volume 9 - 2024, Issue 12 - December
Google Scholar :
https://tinyurl.com/36mwjzzc
Scribd :
https://tinyurl.com/k6wtu62j
DOI :
https://doi.org/10.5281/zenodo.14621428
Abstract :
This study aims to analyze and improve
productivity at PT Manufaktur through the Total
Productive Maintenance (TPM) approach and
measurement of Overall Equipment Effectiveness
(OEE). The problem faced by the company is a
significant decrease in productivity, reflected in the
increase in machine downtime by 25%, product defect
rates reaching 12%, and various losses in the production
process which result in financial losses reaching Rp. 500
million per month. The research method used a
quantitative approach with primary data collection
through direct observation, interviews with operators
and production supervisors, and secondary data in the
form of production, maintenance, and quality control
records during the period November 2023-October 2024.
The analysis was carried out by calculating the OEE
value based on three main components, namely
Availability, Performance rate, and Quality rate, and
identifying the implementation of the eight pillars of
TPM using an assessment matrix and fishbone analysis.
The results showed that the average OEE value was
77.94% (Availability 95.1%, Performance Rate 82.49%,
Quality Rate 99.45%), still below the world class
standard (85%). Losses are caused by breakdown losses
(5%), defect losses (2%), setup and adjustment losses
(3%), reduced speed losses (13%), and idling and minor
stoppage losses (14%). Effective TPM implementation is
recommended through autonomous maintenance,
planned maintenance, quality maintenance, and focused
improvement programs, with a target of increasing the
OEE value to 86% within 12 months. This research also
produced a comprehensive TPM implementation
roadmap along with key performance indicators for
continuous monitoring and evaluation.
Keywords :
TPM, OEE, Six Big Losses, FMEA.
References :
- Agustiady, T. K., & Cudney, E. A. (2016). Strategies and implementation guide. https://b- ok.org/book/2572244/84bbac
- Anthony, M. B. (2019). Analisis Penerapan Total Productive Maintenance (TPM) Menggunakan Overall Equipment Efectiveness (OEE) Dan Six Big Losses Pada Mesin Cold Leveller PT. KPS. JATI UNIK : Jurnal Ilmiah Teknik Dan Manajemen Industri, 2(1), 94. https://doi.org/10.30737/jatiunik.v2i2.333
- Fitriadi, F., Muzakir, M., & Suhardi, S. (2020). Integrasi Overall Equipment Effectiveness (OEE) Dan Failure Mode And Effect Analysis (FMEA) Untuk Meningkatkan Efektifitas Mesin Screw Press Di Pt. Beurata Subur Persada Kabupaten Nagan Raya. Jurnal Optimalisasi, 4(2), 97-107.
- Frima, F. R., Budiasih, E., & Ilhilman, J. (2019). Usulan Penerapan Total Productive Maintenance (tpm) Untuk Meningkatkan Efektivitas Mesin Single. https://openlibrarypublication.telkomuniversity.ac.id/index.php/engineering/article/view/10980
- Guedesa, M., Figueiredo, P. S., Pereira-Guizzoa, C. S., & Loiolab, E. (2021). The role of motivation in the results of total productive maintenance. Production, 31(2006), 1–14. https://doi.org/10.1590/0103-6513.20200057
- Kulsum, K., Febianti, E., Trenggonowati, D. L., & Sutanto, Y. (2020). Review Produktivitas Mesin Menggunakan Total Productive Maintenance (Studi Kasus Perusahaan Manufaktur). Journal Industrial Servicess, 6(1), 40. https://doi.org/10.36055/jiss.v6i1.9472
- Kurnia, N. F. (2019). Penerapan Total Productive Maintenance (TPM) Dengan Menggunakan Metode Overall Equipment Effectiveness (OEE) Dan Failure Mode And Effect Analysis (Fmea) Pada Mesin Jahit Toyota LS2-AD140 (Studi Kasus: CV Manggala Glove).
- Meca Vital. J. C., & Camello Lima, C. R. (2020). Total Productive Maintenance and the Impect of Each Implemented Pillar in the Overall Equipments Effectiveness. International Journal of Engineering and Management Research, 10(02), 142-150. https://doi.org/10.31033/ijemr.10.2.17
- Mtsweni, E. S., Hörne, Dkk (2020). Title. Engineering, Construction and Architectural Management, 25(1),1–9.
- Nugroho, A. J. (2017). Evaluasi Gangguan Jaringan Telepon Menggunakan Metode FTA dan FMEA. https://doi.org/10.23917/jiti.v16i2.2420
- Nurprihatin, F., Angely, M., & Tannady, H. (2019). Total productive maintenance policy to increase effectiveness and maintenance performance using overall equipment effectiveness. Journal of Applied Research on Industrial Engineering, 6(3), 184-199. https://doi.org/10.22105/jarie.2019.199037.1104
- Pandey, A., Malviya, S., & Jain, S. (2019). Implemented the Overall Equipment Effectiveness ( OEE ) by the techniques of Total Productive Maintenance ( TPM ) in MSE ’ s - A case study. International Journal of Advance Research, Ideas and Innovations in Technology, 5(1), 503–511.
- Prasmoro, A. V., & Ruslan, M. (2020). Analisis Penerapan Total Productive Maintenance (TPM) dengan Metode Overall Equipment Effectiveness (OEE) pada Mesin Kneader (Studi Kasus PT. XYZ). Journal of Industrial and Engineering System, I(1), 53-64. https://doi.org/10.31599/jies.vlil.167.
- Pratama, D., & Yuamita, F. (2021). Analisis Efektivitas Mesin Jahit Dengan Overall Equipment Effectiveness (OEE) Dan Failure Mode And Effect Analys (FMEA) (Study kasus : CV. Cahaya Setia Mulia). JIE.UPY Journal of Industrial Engineering Universitas PGRI Yogyakarta, 1(1), 23–30.
- Tian Xiang, Z., & Jeng Feng, C. (2020). Journal of Industrial Engineering and Management Implementing Total Productive Maintenance in a Manufacturing Small or Medium-Sized Enterprise. Journal of Industrial Engineering and Management, 14(2), 152–175. https://doi.org/10.3926/jiem.3286
- Nugroho, Y. A., & Febrianto, E. (2022). Analisis Kinerja Mesin Band Saw Soft Mill Menggunakan Total Productive Maintenance Pada PT. Alis Jaya Ciptatama. https://journal.literasisains.id/index.php/ insologi/article/view/412/258,
- David Rakes, Muhammad Arif, Agus Setiawan, Kerina Putri Nasution & Yudi Prastyo (2024). Preventive Maintenance on CNC Machines Using the (OEE) Method to Reduce Downtime at PT. MTAT. https://jii.rivierapublishing.id/index.php/jii/article/view/5116
This study aims to analyze and improve
productivity at PT Manufaktur through the Total
Productive Maintenance (TPM) approach and
measurement of Overall Equipment Effectiveness
(OEE). The problem faced by the company is a
significant decrease in productivity, reflected in the
increase in machine downtime by 25%, product defect
rates reaching 12%, and various losses in the production
process which result in financial losses reaching Rp. 500
million per month. The research method used a
quantitative approach with primary data collection
through direct observation, interviews with operators
and production supervisors, and secondary data in the
form of production, maintenance, and quality control
records during the period November 2023-October 2024.
The analysis was carried out by calculating the OEE
value based on three main components, namely
Availability, Performance rate, and Quality rate, and
identifying the implementation of the eight pillars of
TPM using an assessment matrix and fishbone analysis.
The results showed that the average OEE value was
77.94% (Availability 95.1%, Performance Rate 82.49%,
Quality Rate 99.45%), still below the world class
standard (85%). Losses are caused by breakdown losses
(5%), defect losses (2%), setup and adjustment losses
(3%), reduced speed losses (13%), and idling and minor
stoppage losses (14%). Effective TPM implementation is
recommended through autonomous maintenance,
planned maintenance, quality maintenance, and focused
improvement programs, with a target of increasing the
OEE value to 86% within 12 months. This research also
produced a comprehensive TPM implementation
roadmap along with key performance indicators for
continuous monitoring and evaluation.
Keywords :
TPM, OEE, Six Big Losses, FMEA.