Analysis for Enhancing Quality and Productivity Using Overall Equipment Effectiveness and Statistical Process Control in Manufacturing Industry Case Study: Manufacturing Industry Sport Shoes in Tangerang Region

Authors : Wahyudin, Budi Irawan Saleh, Sawarni Hasibuan

Volume/Issue : Volume 4 - 2019, Issue 12 - December

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The main problem often faced by the manufacturing industry is the high level of loses time, which is illustrated by the low utilization rate of Total Productive Maintenance (TPM) time and the impact on the low level of effectiveness of the plant or equipment. This is often caused by breakdown losses, setup and adjustment losses, start-up losses, minor stoppage, idling, speed losses, and defect losses. This study aims to determine the time utilization of TPM and provide suggestions for improvements to improve Overall Equipment Effectiveness (OEE) time utilization and lead to savings in production costs. Case studies were carried out on manufacturing companies engaged in sport's shoes and are the largest supplier of world sports shoe brands. Products produced from this industry are the Upper (upper part of the shoe), Outsole (the bottom of the shoe), and Insole (the inside of the shoe) with the main raw materials being leather, foam, and rubber. From the results of data processing, it is obtained the effectiveness value of the manufacturing process, which is OEE, an average of 76.98% per month with a component availability of 94.87%, a performance rate of 41.42%, and a quality rate of 94.74%. The main causes of lost time are defect losses time of 4.74% per month of total productive time and breakdown losses of 2.17% per month of total productive time. Control process measurements are carried out to determine variations in the number of rework products and defects are still in the control limits of statistical control. To make improvements from the actual state, a new standard for product quality is set, from the number of 53 pairs of reworks and B'Grade (defective products sold at half the price of good products) 2 pairs to 47 pairs and 1 pair B’Grade. With the new work program and continuous improvement, it is the factory can reduce the number of rework products and B'Grade defects that can save up to IDR 56,586,860 per month.

Keywords : Total Productive Maintenance, Overall Equipment Effectiveness, Statistical Process Control, Shoe’s Manufacturing Industry.


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