Analisis Total Productive Maintenance pada Mesin D2BM-021 JOMAR EX 15 (II-10) Area Blow Clean Room di PT XYZ

Abstract

PT XYZ adalah perusahaan manufaktur yang bergerak dibidang produksi kemasan plastik. Dalam menjalankan perannya, mesin D2BM-021 JOMAR EX 15 (II-10) yaitu mesin injection blow molding memiliki downtime yang paling tinggi dalam satu bulan terakhir pada area Blow Clean Room. Penelitian ini bertujuan mengidentifikasi penyebab utama kerusakan dan menyusun strategi perbaikan berbasis TPM. Berdasarkan hasil penelitian pada mesin D2BM-021 JOMAR EX 15 (II-10) menunjukkan nilai rata-rata availability rate sebesar 90%, nilai rata-rata performance rate sebesar 92%, dan nilai rata-rata quality yield sebesar 97% dengan perhitungan ketiga rasio tersebut didapatkan nilai rata-rata OEE pada bulan Mei hingga Oktober 2023 sebesar 82%. Untuk losses yang presentasenya paling besar adalah breakdown losses (45%), reduced speed (25%), dan reject losses (12%). Setelah itu, dilakukan analisis kembali dengan metode FMEA dan fishbone diagram dan dilakukan pembuatan rekomendasi perbaikan dengan harapan dapat meningkatkan efektifitas kinerja mesin dan memperkuat praktik TPM pada fasilitas produksi serta dapat dijadikan acuan apabila ada permasalahan tentang efektifitas peralatan pada mesin yang setipe.

PT XYZ is a manufacturing company engaged in packaging production. In fulfilling its role, the D2BM-021 JOMAR EX 15 (II-10) machine, which is an injection blow molding machine, has experienced the highest downtime in the last month in the Blow Clean Room area. This study aims to identify the main causes of malfunctions and develop improvement strategies based on TPM. Based on the research results on the D2BM-021 JOMAR EX 15 (II-10) machine, the average availability rate is 90%, the average performance rate is 92%, and the average quality yield is 97%, resulting in an average OEE value from May to October 2023 of 82%. The most significant losses percentages are breakdown losses (45%), reduced speed (25%), and reject losses (12%). Afterwards, a reanalysis was conducted using the FMEA method and fishbone diagram, leading to the formulation of improvement recommendations for the company, the recommendations are expected to enhance the machine's performance effectiveness, strengthen TPM practices in the production facility, and serve as a reference for addressing equipment effectiveness issues with similar machines.