Penerapan Konsep Total Productive Maintenance Melalui Metode Overall Equipment Effectiveness pada Proses slitting Di PT XYZ

Abstract

PT XYZ menghadapi tantangan rendahnya efektivitas mesin slitting coil akibat tingginya Unplanned downtime karena setup and adjustment losses.dan Equipment Failure. Penelitian ini bertujuan untuk mengukur efektivitas mesin slitting menggunakan metode Overall Equipment Effectiveness (OEE), mengidentifikasi kerugian produksi melalui six big losses, serta menganalisis akar penyebab masalah dengan Fault Tree Analysis (FTA) dan Failure Mode and Effects Analysis(FMEA). Penelitian dilakukan selama delapan bulan (Januari–Agustus 2025) melalui observasi langsung, pengumpulan data historis, wawancara, dan analisis dokumen. Hasil penelitian menunjukkan rata-rata OEE sebesar 75%, masih di bawah standar world class sebesar 85%. Penyebab utama adalah setup and adjustment losses.(13,25%) dan Equipment Failure (9%). Analisis FTA dan FMEA mengidentifikasi proses change over slitting sebagai area paling kritis, terutama ketidakpresisian setting clearance pisau slitter. Rekomendasi perbaikan yang diusulkan meliputi penggunaan shim ring presisi, One Point Lesson (OPL), perbaikan SOP change over, serta form preventive maintenance.

PT XYZ encountered low Machine effectiveness on its slitting line due to high Unplanned downtime because setup and adjustment losses.and Equipment Failure. This study aims to measure the effectiveness of the slitting Machine using Overall Equipment Effectiveness (OEE), identify production losses through six big losses, and analyze the root causes using Fault Tree Analysis (FTA) and Failure Mode and Effects Analysis(FMEA).The research was conducted over eight months (January–August 2025) through direct observation, historical data collection, interviews, and document analysis. The average OEE obtained was 75%, still below the world-class standard of 85%. The main contributors were setup and adjustment losses.(13.25%) and Equipment Failure (9%). FTA and FMEA identified the change over process, particularly inaccuRate slitter knife clearance setting, as the most critical issue. Recommended Improvements include precision shim ring, One Point Lesson (OPL), improved change over SOP, and preventive maintenance checklist.