Authors : Ari Ramdhani; Mohammad Hilman Maulana; Rahmad Hidayat Nasution; Yudi Prastyo

Volume/Issue : Volume 9 - 2024, Issue 12 - December

Google Scholar : https://tinyurl.com/36mwjzzc

Scribd : https://tinyurl.com/k6wtu62j

DOI : https://doi.org/10.5281/zenodo.14621428

Abstract : This study aims to analyze and improve productivity at PT Manufaktur through the Total Productive Maintenance (TPM) approach and measurement of Overall Equipment Effectiveness (OEE). The problem faced by the company is a significant decrease in productivity, reflected in the increase in machine downtime by 25%, product defect rates reaching 12%, and various losses in the production process which result in financial losses reaching Rp. 500 million per month. The research method used a quantitative approach with primary data collection through direct observation, interviews with operators and production supervisors, and secondary data in the form of production, maintenance, and quality control records during the period November 2023-October 2024. The analysis was carried out by calculating the OEE value based on three main components, namely Availability, Performance rate, and Quality rate, and identifying the implementation of the eight pillars of TPM using an assessment matrix and fishbone analysis. The results showed that the average OEE value was 77.94% (Availability 95.1%, Performance Rate 82.49%, Quality Rate 99.45%), still below the world class standard (85%). Losses are caused by breakdown losses (5%), defect losses (2%), setup and adjustment losses (3%), reduced speed losses (13%), and idling and minor stoppage losses (14%). Effective TPM implementation is recommended through autonomous maintenance, planned maintenance, quality maintenance, and focused improvement programs, with a target of increasing the OEE value to 86% within 12 months. This research also produced a comprehensive TPM implementation roadmap along with key performance indicators for continuous monitoring and evaluation.

Keywords : TPM, OEE, Six Big Losses, FMEA.

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