KaizeninWorld Class Automotive Company With Reduction of Six Big Lossesin Cylinder Block Machining Line in Indonesia

Authors : Ahmad Rozak, Amalina Shadrina, Erry Rimawan

Volume/Issue : Volume 4 - 2019, Issue 7 - July

Google Scholar : https://goo.gl/DF9R4u

Scribd : https://bit.ly/2Mj57LJ

Cylinder block machining line in automotive manufacturing in Indonesia has launched a world-class company if reviewed from the achievement of productivity level of production activity and a number of quality products that are calculated using the Overall Equipment Effectiveness (OEE) value that is valued above 85% as mention in JIPM Total Productive Maintenance (TPM) world company standard. Even though it has reached the average OEE from September till November 2018 was 87%, so there was still an opportunity to make improvements of 13%, this company still continues to increase the value of OEE through Kaizen activities. Kaizen is carried out to make improvements to increase the value of Availability, Performance Efficiency, and Rate of Quality. The steps taken to improve OEE, starting with measuring OEE, are continued by calculating six major loses then looking for the biggest factor that affects the increasing OEE value. After that, look for the causes of the problems analyzed using Fishbone Diagrams. Things to do to increase the OEE value are to make improvements at the frequent breakdown machine and the long line stop machine as the priority of the problem. Within one month, we can increase OEE become 92% in December 2018.

Keywords : Total Productive Maintenance, Overall Equipment Effectiveness, Six Major Losses, Kaizen.


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