Penerapan Total Productive Maintenance Berbasis Efektivitas Mesin pada Mesin Ripple Mill di PKS Cikasungka PTPN IV

Abstract

Penelitian ini dilatarbelakangi oleh belum optimalnya kinerja mesin Ripple Mill yang ditandai dengan tingginya downtime sehingga mempengaruhi efektivitas produksi. Penelitian ini bertujuan untuk mengevaluasi kondisi pemeliharaan serta tingkat efektivitas mesin. Metode yang digunakan meliputi analisis keandalan mesin menggunakan Reliability Centered Maintenance (RCM), pengukuran efektivitas menggunakan Overall Equipment Effectiveness (OEE), analisis penyebab menggunakan fishbone diagram, serta penentuan prioritas dengan pairwise comparison. Hasil penelitian menunjukkan nilai OEE sebesar 25% dengan availability 80%, performance 42%, dan quality 74%, dimana performance menjadi faktor terendah. Analisis menunjukkan bahwa faktor dominan berasal dari aspek machine, khususnya komponen as bar, yang didukung oleh analisis pareto, data frekuensi kerusakan dan hasil wawancara. Sebagai upaya perbaikan, disusun One Point Lesson (OPL) untuk mendukung pencegahan dan penanganan awal kerusakan, sehingga diharapkan dapat meningkatkan keandalan mesin dan efektivitas produksi.

This study was motivated by the suboptimal performance of the Ripple Mill machine, as indicated by high downtime, which affects production effectiveness. The objective of this study was to evaluate the maintenance condition and the effectiveness level of the machine. The methods employed included machine reliability analysis using Reliability Centered Maintenance (RCM), effectiveness measurement using Overall Equipment Effectiveness (OEE), root cause analysis using a fishbone diagram, and priority determination through pairwise comparison. The results showed that the OEE value was 25%, with an availability rate of 80%, performance rate of 42%, and quality rate of 74%, where performance was identified as the lowest contributing factor. The analysis indicated that the dominant cause originated from the machine aspect, particularly the shaft bar component, supported by Pareto analysis, failure frequency data, and interview results. As an improvement effort, a One Point Lesson (OPL) was developed to support the prevention and early handling of machine failures, thereby improving machine reliability and production effectiveness.