Application of the Concept of Total Productive Maintenance in Automatic Bottle Filling Machines

Guwatirta Sejahtera is one of the companies engaged in the bottled drinking water industry. Problems that occur at PT. Guwatirta Sejahtera is the absence of routine maintenance on the machine so that damage, especially on automatic bottle filling machines, often occurs. This study applies a total productive maintenance method to determine the level of damage and identify the source of the problem as a basis for making recommendations for improvement in reducing the level of damage that often occurs in automatic bottle filling machines. The stage of the study begins by determining the engine efficiency and six big losses using the Overall Equipment Effectiveness parameter (OEE). Then proceed with identifying the source of the problem using the Failure Mode and Effect Analysis (FMEA) method. Recommendations for improvement include making: a daily inspection checklist, small working groups, Standard Operating Procedures for operating the machine and routine maintenance schedules. Based on the estimated calculation if the recommendation for improvement is applied, the value of the original engine efficiency of 84.26% increased to 98.97% and the initial maintenance costs of Rp.81,232,369.48 decreased to Rp.75,355,764.39 per year

Model for improvement of overall equipment effectiveness of beerfilling lines

In this article, the efficiency loss of a beer filling line is investigated and modeled to improve its system performance in terms of overall equipment effectiveness and productivity. First, research is aimed at problems related to beer filling line resulting from poor production management where utilization and productivity of filling machines are low. This article derives the overall equipment effectiveness of filling machines and overall throughput effectiveness of the filling line, with the overall throughput effectiveness of general system (OTE(S)) obtained based on these measurements. Based on these metrics, the efficiency evaluation system is established. Next, according to the efficiency evaluation indexes, overall equipment effectiveness, and OTE(S), the overall efficiency of filling machines and filling line are calculated, respectively. From the results, the stenciling machine has the lowest efficiency. However, considering overall throughput effectiveness indexes and production capacity, unit 3 is the bottleneck and limits the entire productivity. Finally, efficiency loss is analyzed based on the overall equipment effectiveness and OTE(S) calculation results. Using a fishbone diagram for analysis, the cause of equipment loss is summarized and countermeasures are offered. Theory of constraint is used to analyze the efficiency loss of the filling line and give suggestions for improvement. This research can help beer enterprises achieve continuous improvement of equipment efficiency and production capacity.