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%.

Reliability analysis and hypothesis testing of critical success factors of total productive maintenance

PurposeThis paper deals with concept of total productive maintenance (TPM) and its implementation approach. It also presents the identification of critical factors for effective implementation of TPM. The reliability analysis identified potential areas where more concentration is required. The application of hypothesis testing in productivity maintenance should be promoted by parametric test and significantly instrumental in explanation of phenomena. It is also indispensable to better understand quality data and provide guidance to production control.Design/methodology/approachThe various critical success factors of TPM implementation has organised into set of eight performance measure and thirty three sub-factors for getting the in-depth details of each indicator. The paper identifies the reliability of these factors and understands the problem with greater clarity and its ramification. Researcher collected responses from forty one manufacturing organisations through structured designed questionnaire. The reliability analysis was carriedout by calculating the value of Cronbach's alpha method. To draw the meaningful conclusions supported by relevant empirical data, provisional formulation is required, and it was carried by hypothesis testing. In this test, samples are taken from a population with known distribution (normal distribution), and a test of population parameters is executed. It determines the relevancy of facts directs the researcher's efforts into productive channels. The statements were hypothetically tested by calculating the arithmetic value of Chi-Square (χ2) and MINITAB-19 software was used for identification of p-value.FindingsThis study identified that main factors and sub-factors of TPM which are critical for implementation of TPM. The study also avoids the complexities involved in implementing TPM by reliability analysis. It is found that all identified CSFs are reliable as Cronbach's alpha is above 0.6. The hypothesis testing shows that all alternative hypothesis statements are acceptable as Chi-Square (χ2) value has satisfied the conditions and null hypothesis are true as calculated p-value is less than the 0.05 for eight identified TPM critical factor.Originality/valueIn this paper researcher provides a comprehensive typology of TPM-CSFs, and its ranking and importance in manufacturing sector. The preparedness of such study related to TPM implementation is becoming a major sourcing base for the world and there is a paucity of such studies. Such studies are equally important in a global context.

A review on the identification of total productive maintenance critical success factors for effective implementation in the manufacturing sector

PurposeThe purpose of this paper is to carry out the literature search on manufacturing organizations and total productive maintenance (TPM). This research aims at studying TPM attributes and barriers in line with the TPM framework for effective implementation of TPM. This study identifies the barriers in TPM implementation and the critical success factors (CSFs) for effective TPM implementation.Design/methodology/approachIn this manuscript, the study of TPM in the manufacturing sector has been considered a broad area of the research and emphasis on the TPM literature review, which primarily relates to the contribution of manufacturing sector and employment availability. Next sections covers TPM history, importance, justification, pillars, obstacles and TPM implementation procedure and models. Thereafter author identified the gaps in existing literature.FindingsThe existing literature shows that very few TPM implementation models are available for the manufacturing sector. The study also found that there is no systematically conducted large-scale empirical research which deals with TPM implementation. In order to bridge this gap, an investigation into the successful implementation of TPM in is truly needed. The finding of the literature shows that there is a need of TPM model specially developed for the manufacturing sector. The identified critical factors derived from the extensive literature review help to overcome the barriers for effective TPM implementation.Research limitations/implicationsThis review study is limited to Indian manufacturing industries. The identified TPM CSFs are based on the TPM pillars and their sub-factors. This cross-sectional study was based on the existing TPM model.Practical implicationsThis paper can increase the significance of TPM strategy, which could help managers of organizations to have a better understanding of the benefits of implementing TPM and therefore enable patient satisfaction within their organizations.Originality/valueThe literature review covers methodical identification of TPM barriers and critical factors for maintenance performance improvements. It allows the practitioners to apply these identified CSFs for TPM implementation to achieve an improvement in industrial performance and competitiveness.

ANALISIS PENGENDALIAN KUALITAS MENGGUNAKAN METODE SIX SIGMA DALAM MENINGKATKAN KINERJA OPERASIONAL DIVISI FIXED PLANT MAINTENANCE DI INDUSTRI PERTAMBANGAN PT BERAU COAL

Penelitian ini bertujuan untuk mengetahui peningkatan efektivitas mesin coal crusher dengan menggunakan analisis deskriptif dan kuantitatif metode six sigma. Penggunaan Overall Equipment Effectiveness dan Six Big Losses untuk menentukan nilai Overall Equipment Effectiveness dan faktor dominan yang menyebabkan rendahnya kinerja mesin atau peralatan. Proses penerapan small group activity sebagai bagian dari Total Productive Maintenance dengan penerapan fase DMAIC dari analisis Overall Equipment Effectiveness (OEE), Six Big Losses, dan Fish Bone Diagram untuk menganalisa penyebab masalah yang menghambat kinerja mesin dan peralatan serta signifikansi peningkatan kinerja operasional di departemen FPM. Berdasarkan pengolahan data pada Coal Crusher dengan metode OEE dan Six Big Losses faktor yang paling dominan menyebabkan rendahnya kinerja mesin adalah Reduced Speed Losses dengan persentase 58,82% dan Equipment Failure Losses dengan persentase 62,21% pada mesin Coal Crusher yang mempengaruhi efektivitas dan produktivitas mesin tersebut. Menggunakan diagram pareto untuk menganalisis data losses yang ada sehingga akar permasalahan dapat ditemukan. Selanjutnya dengan analisis fish bone diagram didapatkan saran-saran langkah pencegahan dalam mengurangi jumlah losses time. Langkah perbaikan sistem yang dilakukan di Departemen FPM dengan penerapan Small Group Activity sebagai control secara berkelanjutan memberi peningkatan produktivitas terhadap kinerja Coal Crusher di akhir periode Desember 2020 yaitu diperoleh rata-rata nilai Overall Equipment Effectiveness (OEE) yaitu sebesar 87% dan telah memenuhi nilai standar dunia 85%. Dengan adanya peningkatan kinerja diharapkan kegiatan proses produksi dapat berjalan efektif, efisien, serta energi dapat digunakan secara optimal.

Desain Media Interaktif (Interactive Dashboard) Sentralisasi Data Total Productive Maintenance di 44 Unit Cilacap Plant PT Solusi Bangun Indonesia Tbk

Industri semen tidak terlepas dari maintenance, data mengenai management perawatan fasilitas menjadi penting untuk diketahui semua orang agar bisa selalu memantau kondisi equipment dan lingkungan pabrik apabila terjadi abnormalitas, namun di PT Solusi Bangun Indonesia Tbk, Cilacap Plant masih menggunakan metode konvensional (paperbased) dalam record perawatan, hal ini kurang efektif dan efisien maka dari itu dilaksanakan proyek pembuatan media interaktif sebagai sentralisasi data dengan mengembangkan kaidah industri 4.0. Media interaktif (interactive dashboard) total productive maintenance bertujuan untuk mensentralisasi data terkait management perawatan fasilitas. Media interaktif ini dibuat dengan memanfaatkan google Apps seperti google form, google site, serta google spreadsheet dan formula yang terdapat di dalamnya dan disatukan dalam bentuk website yang dikemas dalam bentuk QR code.Output yang dihasilkan yaitu website untuk menampilkan informasi mengenai jadwal dan prosedur perawatan mesin dan atau fokus area tertentu. Management lebih mudah untuk menilai dan memberikan review terkait pekerjaan yang berhubungan dengan TPM di lapangan dengan hanya melalui satu genggaman saja

How Organizational Culture Moderate the Effect of Total Productive Maintenance Practice on Organization’s Operational Performance? Evidences from Indonesian Mining Industry

The industry needed a system to support its operation when most of the processes were done by equipment or machines. Total Productive Maintenance (TPM) was a system to ensure all equipment or machines run in optimal performance for long period by fully supported by top management until the bottom level. Implementation of this system in the mining industry was still seldom due to some factors and organizational culture was one of the reasons. The purpose of this research was to analyze the influence of TPM implementation on operational performance by moderating the effect of organizational culture in the mining industry by using a two-step approach of structural equation model (SEM). The research type was under explanative research with hypothesis testing from primary data that was obtained from distributing questionnaires and direct interviews in the field which was analyzed by using Lisrel 8.7. This research showed that the construct of TPM has a significant impact to influence operation performance directly in the mining industry with a t-value of 3.54 and organization culture also increases the significance by moderating effect with t-value of interaction 5.28 was higher than 1.96 while organizational culture was not significant to influence operational performance directly that was showed by t-value 1.22. This research had a novelty for studying TPM practice in Indonesian mining by using SEM to analyze the moderating effect of organizational culture. The managerial implication of this research was a guideline for decision-makers to implement TPM by considering developing, group, hierarchical, and rationale culture to improve operational performance in the Indonesian mining industry.

A Systematic Literature Review of Total Productive Maintenance On Industries

Attempts to achieve optimization of machine and equipment maintenance at manufacturing companies over the years have encountered a multitude of problems. Due to equipment losses such as setup and adjustment, minor stops and delays, defective products due to equipment, reduced engine speed, and reduced output has influenced their desire to reach world class manufacturing levels. This paper discusses a large part of the TPM approach in manufacturing companies and provides an overview of the various TPM implementation practices demonstrated by manufacturing companies in the world.. Based on review results of the 50 journals about TPM in industries It was found that most of the TPM implementations used the OEE parameter to see the success rate of implementing this TPM. This paper also highlights the variable approach that is most widely used by various practitioners and researchers and evaluates in detail the success factors of implementing TPM and the reasons behind the failure of implementing TPM are also discussed so as to ensure the implementation of TPM can run smoothly and effectively in manufacturing companies