Optimalisasi Performance Rate Mesin Filling Berdasarkan Analisis Six Big Losses Untuk Meningkatkan OEE di PT XYZ

Abstract

PT XYZ memproduksi minuman dalam kemasan menggunakan mesin filling hot fill Yuhfeng HTST yang beroperasi sejak 2008. Nilai OEE mesin filling produk X 200ML periode Juli-Desember 2025 rata-rata sebesar 63,28%, di bawah standar world class 85%, dengan performance rate sebagai komponen terendah rata-rata 77,42%. Penelitian ini bertujuan menganalisis OEE dan Six Big Losses, mengidentifikasi faktor dominan penyebab rendahnya performance rate, serta menyusun rekomendasi perbaikan menggunakan Diagram Pareto, fishbone, 5 Why, dan PDCA. Hasil analisis menunjukkan Reduced Speed Losses (RSL) merupakan kerugian dominan rata-rata 32,75% yang disebabkan fluktuasi suhu PHE sterilizer akibat valve CPM aus karena tidak adanya jadwal Preventive Maintenance baku. Rekomendasi perbaikan meliputi penggantian valve CPM, penetapan jadwal PM bulanan, One Point Lesson (OPL), dan Checksheet PM. Proyeksi menunjukkan availability rate meningkat dari 81,95% menjadi 89,45%, performance rate dari 77,42% menjadi 85,00%, dan OEE dari 63,28% menjadi 75,53% atau naik sebesar 12,25%.

PT XYZ produces bottled beverages using a Yuhfeng HTST hot fill machine operating since 2008. The OEE of the filling machine for product X 200ML during July-December 2025 averaged 63.28%, below the 85% world class standard, with performance rate as the lowest component at 77.42%. This study aimed to analyze OEE and Six Big Losses, identify the dominant factor causing low performance rate, and develop improvement recommendations using Pareto Diagram, fishbone, 5 Why, and PDCA. Results showed that Reduced Speed Losses (RSL) was the dominant loss at 32.75%, caused by PHE sterilizer temperature fluctuations due to worn Constant Pressure Modulating (CPM) valve from lack of a standardized Preventive Maintenance schedule. Recommendations include CPM valve replacement, monthly PM scheduling, One Point Lesson (OPL), and PM Checksheet. Projections indicate availability rate increasing from 81.95% to 89.45%, performance rate from 74.42% to 85.00%, and OEE from 63.28% to 75.53%, a 12.25% improvement.