ANALISIS TPM MESIN PEMOTONG TEKSTIL OTOMATIS CNC-CUTTER KURIS DENGAN METODE OEE DI PT. YIFAN JAYA

Mesin CNC-Cutter C 3030 menjadi salah satu mesin pemotong otomatis tekstil yang cukup diandalkan dalam meningkatkan efisiensi waktu produksi. Mesin ini berfungsi sebagai mesin pemotong otomatis kain atau tekstil dengan menggunakan program sehingga desain yang sudah dibentuk bisa langsung input ke mesin dan mesin akan memotong kain sesuai desain. Tujuan penelitian ini dimaksudkan untuk mengetahui nilai efektivitas produksi pada mesin CNC-Cutter C 3030, nilai efektivitas meliputi availability, performance rate dan quality rate, meode penelitian yang dilakukan dengan metode total productive maintenance, setelah dilakukan penelitian didapatkan Nilai availability sebesar 86,26% pada setiap minggu, Nilai performance rate, quality Rate mesin menunjukan hasil sebesar 96,8%, dan hasil perhitungan Overall Equipment Effectiveness adalah 80,83%.

Improvement of Overall Equipment Effectiveness (OEE) through Implementation of Total Productive Maintenance (TPM) in Manufacturing Industries

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.761.180 ◽

2015 ◽

Vol 761 ◽

pp. 180-185 ◽

Cited By ~ 1

Author(s):

Nazrul Idzham Kasim ◽

Mohd Azam Musa ◽

Akhtar Razul Razali ◽

Noraishah Mohamad Noor ◽

Wan Ahmad Najmuddin Wan Saidin

Keyword(s):

Customer Satisfaction ◽

Performance Index ◽

Production Management ◽

Manufacturing Industries ◽

Maintenance Management ◽

Electronic Industry ◽

Maintenance System ◽

Key Performance Index ◽

Today competitive manufacturing requires innovative approaches in the production management, as well as for customer satisfaction. Production management requires an effective and efficient maintenance management system. One approach to improve the performance of the maintenance system is through the implementation of Total Productive Maintenance (TPM). The key performance index to measure the effectiveness of TPM implementation is Overall Equipment Effectiveness (OEE). The TPM activities will eliminate equipment losses related to availability, performance rate, and quality rate. Hence, the TPM implementation will increase the OEE value. This paper outlines the theories of TPM and OEE. The paper also presents the studies carried out by different authors to show the improvement of OEE through implementation of TPM in manufacturing, such as electronic industry, steel manufacturer, as well as locomotive components manufacturer.

Sistem Informasi Produktifitas Mesin dengn Metode Overall Equipment Effectiveness

Jurnal Teknologi dan Ilmu Komputer Prima (JUTIKOMP) ◽

10.34012/jutikomp.v1i2.245 ◽

2018 ◽

Vol 1 (2) ◽

pp. 52-60

Author(s):

Tri Ngudi Wiyatno ◽

Muhamad Fatchan ◽

Andri Firmansyah

Keyword(s):

Rate Performance ◽

Pada dunia industri yang semakin kompetitif, maka dibutuhkan adanya dukungan teknologi dalam kegiatan produksi, untuk mengetahui produktifitas kegiatan produksi salah satunya dengan melakukan pengukuran produktifitas mesin produksi, untuk itu maka perlu dilakukan pendekatan multi disipliner yang melibatkan semua usaha, kecakapan, keahlian, modal, teknologi, manajemen, informasi dan sumber-sumber daya lainnya secara terpadu. Salah satu pendekatan dalam meningkatkan produktifitas mesin adalah dengan menerapkan Total Productive Maintenance (TPM) yaitu dengan melakukan pengukuran nilai Overall Equipment Effectiveness (OEE) terhadap mesin produksi sehingga dapat diketahui tingkat produktifitas mesin saat beroperasi. Metode perhitungan OEE berfungsi untuk melihat secara keseluruhan produktifitas mesin saat beroperasi yang mencakup tiga faktor yaitu Availability Rate, Performance Rate dan Rate of Quality. Penelitian ini merancang sistem informasi perhitungan nilai OEE pada unit mesin saat beroperasi yang bertujuan untuk mempermudah mendapatkan informasi terhadap kinerja mesin secara up to date, sehingga diharapkan dengan informasi tersebut perusahaan dapat melakukan perbaikan-perbaikan guna meningkatkan produktifitas mesin secara cepat dan tepat sasaran sehingga dapat memenuhi target produksi yang telah ditetapkan oleh perusahaan. Hasil perancangan sistem informasi OEE ini diterapkan di PT XYZ pada unit mesin Packing dengan mengambil waktu operasi pada bulan September 2018, dari pengambilan data dan pengolahan data kedalam sistem informasi OEE, maka didapat nilai Availability Rate 91,63% , Performance rate 72,61%, Quality rate 98,4% dan OEE 65,48% . Rendahnya nilai OEE mesin packing disebabkan karena Performance mesin tersebut rendah(72,61%) , ini berarti mesin tersebut beroperasi dengan kecepatan dibawah standart.

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 ◽

10.31599/jies.v1i1.167 ◽

2020 ◽

Vol 1 (1) ◽

pp. 53-64

Author(s):

Alloysius Vendhi Prasmoro ◽

Muhamad Ruslan

Keyword(s):

Environmental Factors ◽

Manufacturing Companies ◽

Machine Material ◽

Breakdown Rate ◽

Efficiency And Effectiveness ◽

Maintenance Work ◽

World Class ◽

Performance Rate ◽

Production Target

ABSTRACT PT. XYZ has implemented Total Productive Maintenance (TPM) to improve the efficiency and effectiveness of manufacturing companies as a whole. However, the implementation is still not optimal and seen from not achieving the production target. This study aims to measure the value of the effectiveness of equipment, find the root causes of problems and provide suggestions for improvement. The study was conducted on a kneader machine that had the highest breakdown rate. This research begins by measuring the overall equipment effectiveness (OEE) achievement value, then identifying the six big losses that occur. The results showed that the average OEE value on the kneader machine was 81.62%, the effectiveness value was classified as very low because the standard OEE value for world-class companies was ideally 85%. The biggest factor influencing the low OEE value is the performance rate with a factor of six big losses in reducing spees losses of 42.66% and idling and minor stoppages of 31.27% of all time losses. What causes the magnitude of losses consists of human, machine, material, method, and environmental factors. Human and machine factors are the most dominant factors. To reduce these losses, companies should provide skills and knowledge training to operators about the signs of damage to the equipment. In addition, operators are given additional work in the form of equipment maintenance that is often used in work so that maintenance work can be more focused. Then the company must pay more attention to the comfort of the operator at work so that fatigue can be reduced and operator productivity is increased and increase operator awareness of the tools they use. Keywords: Overall Equipment Effectiveness (OEE), Six Big Losses, Idling and Minor Stoppages ABSTRAK XYZ telah menerapkan Total Productive Maintenance (TPM) guna meningkatkan efisiensi dan efektivitas perusahaan manufaktur secara menyeluruh. Namun dalam pelaksanaannya masih belum optimal dan dilihat dari tidak tercapainya target produksi. Penelitian ini bertujuan untuk mengukur nilai efektivitas peralatan, mencari akar penyebab masalah dan memberikan usulan perbaikan. Penelitian dilakukan pada mesin kneader yang selama ini memiliki tingkat breakdown yang tertinggi. Penelitian ini dimulai dengan mengukur pencapaian nilai overall equipment effectiveness (OEE), kemudian mengidentifikasi six big losses yang terjadi. Hasil penelitian menunjukan bahwa rata-rata nilai OEE pada mesin kneader sebesar 81,62%, nilai efektivitas ini tergolong sangat rendah karena standar nilai OEE untuk perusahaan kelas dunia idealnya adalah 85%. Faktor terbesar yang mempengaruhi rendahnya nilai OEE adalah performance rate dengan faktor persentase six big losses pada reduce spees losses 42,66% dan idling and minor stoppages sebesar 31,27% dari seluruh time losses. Yang menyebabkan besarnya losses terdiri dari faktor manusia, mesin, material, metode, dan lingkungan. Faktor manusia dan mesin merupakan faktor yang paling dominan. Untuk mengurangi kerugian tersebut, perusahaan sebaiknya memberikan pelatihan skill dan pengetahuan kepada operator tentang tanda-tanda kerusakan alat tersebut. Selain itu operator diberikan tambahan pekerjaan berupa perawatan peralatan yang sering digunakannya dalam bekerja sehingga pekerjaan bagian maintenance bisa lebih berfokus. Kemudian perusahaan harus lebih memperhatikan kenyamanan operator dalam bekerja sehingga kelelahan bisa dikurangi dan produktivitas operator lebih meningkat serta meningkatkan kepedulian operator terhadap alat yang digunakannya.

Evaluasi Efektivitas Mesin Kiln dengan Penerapan Total Productive Maintenance pada Pabrik II/III PT Semen Padang

Jurnal Optimasi Sistem Industri ◽

10.25077/josi.v13.n1.p454-485.2014 ◽

2016 ◽

Vol 13 (1) ◽

pp. 454

Author(s):

Andita Rahayu

Keyword(s):

Engine Performance ◽

Average Value ◽

Low Efficiency ◽

And Performance ◽

Equipment Utilization ◽

Quality Of Products ◽

Performance Rate ◽

A Company

PT Semen Padang is a company that produces cement and it can not be separated from issues related to the effectiveness of the machinery/ equipment caused by factors such as six big losses. It can be indicated from the frequency of damage caused to machinery/ equipment because of the damage so that production targets are not achieved. Another result of damage caused by machinery/ equipment is the quality of products where the products are not meet the quality standards. Therefore, it is necessary to measure effective and efficient in the maintenance of machinery/equipment int term of solving such problems. TPM is a method which developed in Japan that can be applied to improve the productivity and efficiency of production. The applied method is one of useful methods to mantain machinery/equipment utilization including, losses that called by the six big losses. One goal of TPM is to increase the effectiveness to improve function and performance of machinery/ equipment used and reduce the six big losses contained in the machine/ equipment. Study has been conductedin W1 and W2 Kiln engine on Indarung Factory II / III PT Semen Padang. The first stage is measuring the effectiveness of W1 and W2 Kiln machine using OEE method. Furthermore, we are y measure OEE Six Big Losses and another losses that lead to the low efficiency of the Kiln machine. The data has been collected based on year 2013. Result showed that the value of OEE in W1 kiln ranged from 49% to 96%. While the value of OEE in W2 kiln ranged from 60% to 98% . It is related to the level of availability W1 kiln (average 92%) were also quite low when it is compared to the level of availability W2 kiln (average 94%) due to the length of time the kiln W1 engine damage. Refer to the value of the performance rate W1 and W2 kiln, it can be concluded that the average value of both engine performance rate is almost the same, ranging between 91% and 92%. Analysis of OEE Six Big Lossesshowed that cause of low OEE on kiln machine is breakdown loss. It also affected the reduced speed loss.Keyword : OEE, Six Big Losses, Availability, Performance Rate, Quality RateAbstrakPT Semen Padang merupakan sebuah perusahaan yang memproduksi semen juga tidak terlepas dari masalah yang berkaitan dengan efektivitas mesin/peralatan yang diakibatkan oleh faktor six big losses tersebut. Hal ini dapat terlihat dari frekuensi kerusakan yang terjadi pada mesin/peralatan karena kerusakan tersebut sehingga target produksi tidak tercapai. Akibat lain yang ditimbulkan kerusakan mesin/peralatan yaitu dalam hal kualitas produk yang dihasilkan dimana produk yang tidak sesuai dengan standar kualitas akan dioleh kembali. Oleh karena itu diperlukan langkah-langkah efektif dan efisien dalam pemeliharaan mesin/peralatan untuk dapat menanggulangi dan mencegah masalah tersebut. TPM adalah salah satu metode yang dikembangkan di Jepang yang dapat digunakan untuk meningkatkan produktivitas dan efisiensi produksi perusahaan dengan menggunakan mesin/peralatan secara efektif. Tidak tepatnya penanganan dan pemeliharaan mesin/peralatan tidak hanya menyebabkan masalah kerusakan saja, tetapi juga kerugian lain yang disebut dengan six big losses. Salah satu tujuan TPM adalah untuk meningkatkan efektivitas dengan cara meningktaan fungsi dan kinerja mesin/peralatan yang digunakan dan mengeliminasi six big losses yang terdapat pada mesin/peralatan. Objek yang diteliti pada penelitian ini adalah mesin Kiln W1 dan W2 yang terdapat pada Pabrik Indarung II/III PT Semen Padang. Tahapan pertama dalam usaha peningkatan efisiensi produksi pada perusahaan ini adalah dengan melakukan pengukuran efektivitas mesin Kiln W1 dan W2 dengan menggunakan metode OEE yang kemudian dilanjutkan dengan pengukuran OEE Six Big Losses dan dari faktor six big losses tersebut dicari faktor terbesar yang mengakibatkan rendahnya efisiensi mesin Kiln. Data yang digunakan adalah data satu tahun terakhir yaitu Bulan JanuariDesember 2013. Selama periode tersebut, diperoleh nilai OEE pada kiln W1 berkisar antara 49% hingga 96%. Sedangkan nilai OEE mesin kiln W2 berkisar antara 60% hingga 98%. Hal ini berhubungan dengan tingkat availability mesin kiln W1 (rata-rata 92%) yang juga cukup rendah bila dibandingkan dengan tingkat availability mesin kiln W2 (rata-rata 94%) dikarenakan lamanya waktu kerusakan mesin kiln W1. Bila dilihat dari nilai performance efficiency mesin kiln W1 dan W2, maka dapat disimpulkan bahwa nilai rata-rata performance efficiency kedua mesin ini hampir sama, yaitu berkisar antara 91% dan 92%. Bila dilakukan analisa OEE Six Big Losses, maka yang menjadi penyebab rendahnya OEE pada mesin kiln ini adalah waktu kerusakan mesin yang tergolong dalam frekuensi sering. Hal ini juga berimbas pada penurunan kecepatan kerja mesin kiln.Kata Kunci : OEE, Six Big Loss, Availability, Performance Rate, Quality Rate

Evaluation of overall equipment effectiveness in concrete block manufacturing

Journal of Techniques ◽

10.51173/jt.v1i1.85 ◽

2020 ◽

Vol 1 (1) ◽

pp. 6-17

Author(s):

Huthaifa Alkhazraji ◽

Sohaib Khlil ◽

Zina Alabacy

Keyword(s):

Manufacturing System ◽

Concrete Block ◽

Three Dimensions ◽

Critical Dimensions ◽

Average Value ◽

Manufacturing Operations ◽

World Class ◽

Performance Rate ◽

Made In

Companies are required to integrate a set of critical dimensions in order to measure and evaluate their performance to compete in globally competitive markets. Overall Equipment Effectiveness (OEE) is a quantitative metric, in the context of the total productive maintenance (TPM), attempts to measure and improve the effectiveness of manufacturing operations in three dimensions namely: availability, performance rate and quality rate. This study applies OEE to evaluate and improve the performance of a concrete block manufacturing system at Dler Company in Iraq. The study was conducted in two years of operation during 2016 and 2017. Results from 2016 show that the level of effectiveness was lower than the world class. An improvement in the average value of the OEE for 2017 was recorded, where the OEE value is increased in 2017 to 75% in comparison with its value in 2016 at 67%. It was also found that the reasons for this improvement are due to the enhancement that are made in the availability and quality.

Analisis Efektivitas Mesin pada Divisi Pengalengan Jamur Di PT. Suryajaya Abadiperkasa Menggunakan Metode Overall Equipment Effectiveness

Jurnal Nasional Teknologi Terapan (JNTT) ◽

10.22146/jntt.56619 ◽

2020 ◽

Vol 3 (1) ◽

pp. 87

Author(s):

Aditya Haradito ◽

Iman Sabarisman ◽

Satria Bhirawa Anoraga

Keyword(s):

Production Line ◽

Best Practice ◽

Rate Performance ◽

Maintenance Schedule ◽

Before And After ◽

Equipment Utilization ◽

Performance Rate ◽

Canning Industry ◽

And Training

PT Suryajaya Abadiperkasa is a food canning industry. Nowadays, many companies are looking up for the alternatives to increase the company revenue by making a continous improvement in every process. This study has three aims to be achieved. First, knowing the value of availability rate, performance rate, and quality rate. Second, to determine the major cause which affecting the effectiveness value of the production machine. Third, to obtain the alternatives improvement to increase the machine effectivity. Overall Equipment Effectiveness (OEE) is a method to determine the effectiveness level of equipment utilization. The OEE method is known as one of the program applications of Total Productive Maintenance (TPM). This study measures the value of OEE in the production line of mushroom canning within two months. The values of this study are, availability rate is 89.99%, performance rate is 65.13%, and quality rate is 99.76%. From those data, the obtained calculation value of OEE is 58.71%, it shows that it has not reach yet the best practice (85%) and need an improvement. The Losses in PT Suryajaya Abadiperkasa are breakdown losses, setup and adjustment losses, idle and minor stoppage losses, and defect losses. The alternatives improvement are tightening the maintenance schedule, as well as inspection before and after use on the machine. This maintenance is supported by a focus on the TPM pillar of self-improvement, which changes the workers’ mindset, to change the mindset of the workers there should be an education and training to improve the ability of workers.

Penerapan Efektivitas Mesin Debarker Menggunakan Overall Equipment Effectiveness (Studi pada PT. Tri Tunggal Laksana Unit Blitar)

JURNAL TEKNOLOGI DAN MANAJEMEN INDUSTRI ◽

10.36040/jtmi.v6i2.3012 ◽

2020 ◽

Vol 6 (2) ◽

pp. 12-17

Author(s):

Sigit Dwi Cahyono ◽

Fourry Handoko ◽

Nelly Budiharti

Keyword(s):

Failure Mode ◽

Performance Ratio ◽

Risk Priority Number ◽

Effect Analysis ◽

Availability Ratio ◽

World Class ◽

Total Productive Maintenance atau TPM adalah salah satu metode proses maintenance yang dikembangkan untuk meningkatkan produktifitas di area kerja, dengan cara membuat proses tersebut lebih reliable dan lebih sedikit terjadi pemborosan (waste). PT. Tri Tunggal Laksana menggunakan mesin debarker sebagai alat pemotong dan pengupas kulit kayu dalam memproduksi veneer. Selama periode produksi, mesin sering mengalami downtime sehingga mengganggu proses kerja produksi. Untuk itulah perusahaan perlu melakukan evaluasi atas mesin yang digunakan sehingga penerapan Total Productive Maintenance dapat dilaksanakan optimal demi meningkatkan efektivitas mesin produksi. Penelitian ini bertujuan menilai efektivitas mesin debarker menggunakan metode Overall Equipment Effectiveness (OEE). Hasilnya, semua faktor yang mempengaruhi nilai OEE berada dibawah standar dunia. Nilai availability ratio (89,78 % < 90,00%), performance ratio (87,97% < 95,00%), dan nilai quality ratio (91,43% < 99,90%). Nilai OEE mesin debarker sebesar 72,1% yang berarti masih berada di bawah world class standart yaitu sebesar 85%. Hasil analisis menunjukkan nilai performance rate yang rendah dipengaruhi oleh adanya komponen–komponen mesin yang kritis dan sering mengalami gangguan. Melalui Failure Mode and Effect Analysis (FMEA) diketahui bahwa komponen rantai conveyor dan mata pisau memiliki nilai Risk Priority Number (RPN) tertinggi sehingga komponen ini yang harus diutamakan dalam upaya meningkatkan efektivitas produksi.

Implementation of Autonomous Maintenance in Total Productive Maintenance

Procedia of Engineering and Life Science ◽

10.21070/pels.v1i2.914 ◽

2021 ◽

Vol 1 (2) ◽

Author(s):

Juli Guritno ◽

Atikha Sidhi Cahyana

Keyword(s):

Rate Performance ◽

Increase Productivity ◽

Pvc Pipe ◽

The purpose of this research is to increase the Avaibility rate, Performance rate and OEE value on pipe extruder line 9 at PT. Wahana Tunas Utama Rucika which is engaged in manufacturing PVC pipe products (Poly Vinyl Clhoride). In order to increase productivity, Total Productive Maintenance (TPM) is measured by calculating OEE. The method used in solving this problem the 8 pillars of TPM with the Autonomous Maintenance (AM) method. The implementation of the TPM pillar aims to increase the knowledge, responsibility and skills of production operators related to machines, so that overall productivity will increase. AM uses a structured and documented system so that this program can run consistently. The results of the implementation of the proposed improvements showed that the Availability rate had to increase by 3.61%, the Performance rate had to increase by 3.41% and OEE had to increase by 3.25% after the proposed improvements 6 months.