Perancangan Total Productive Maintenance untuk Mengurangi Downtime pada Mesin Injection di PT XYZ

Abstract

Penelitian dilakukan berdasarkan latar belakang, yaitu tingginya downtime yang terjadi pada mesin injection molding LG 1300 di PT XYZ, sehingga menyebabkan penurunan tingkat efektivitas produksi. Permasalahan tersebut dikarenakan belum optimalnya penerapan preventive maintenance, kurangnya sistem monitoring mesin, serta belum diterapkan Total Productive Maintenance (TPM). Penelitian yang dilakukan bertujuan untuk merancang sistem TPM berbasis data untuk meningkatkan efektivitas mesin, mengurangi downtime dan menekan cost maintenance dengan menggunakan analisis perhitungan Overall Equipment Effectiveness (OEE), realibility maintenance, serta Root Cause Analysis (RCA). Hasil penelitian menunjukkan bahwa perusahaan membutuhkan sistem maintenance melalui penerapan TPM dengan menerapkan preventive maintenance, monitoring downtime, One Point Lesson (OPL), failure tags, dan sistem SAP berbasis Excel.

This research was conducted in response to the high level of downtime experienced by the LG 1300 injection molding machine at PT XYZ, which has led to a decline in production efficiency. These issue stem from the suboptimal implementation of preventive maintenance, the lack of a machine monitoring system, and the absence of Total Production Maintenance (TPM). The study aimed to design a data-driven TPM system to improve machine effectiveness, reduce downtime, and lower maintenance costs by utilizing Overall Equipment Effectiveness (OEE) analysis, reliability maintenance, and Root Cause Analysis (RCA). The results showed that the company needs a maintenance system based on TPM implementation, including preventive maintenance, downtime monitoring, One Point Lesson (OPL), failure tags, and an Excel-based SAP system.