Analisis Penerapan Total Productive Maintenance pada Mesin Continuous Scouring Bleaching di PT XYZ

Abstract

PT XYZ adalah perusahaan tekstil di Padalarang, Kabupaten Bandung Barat, Jawa Barat. Mesin Continuous Scouring Bleaching (CSB) mencatat jumlah breakdown tertinggi selama periode 2025, sehingga diperlukan analisis Total Productive Maintenance (TPM). Penelitian bertujuan mengetahui efektivitas mesin melalui Overall Equipment Effectiveness (OEE), mengidentifikasi penyebab tingginya downtime menggunakan six big losses, dan merumuskan usulan perbaikan. Data dikumpulkan melalui observasi, wawancara, dan dokumen perusahaan periode 2025. Hasil OEE rata-rata sebesar 49%, dengan availability 82%, Performance 65%, dan quality yield 92% masih jauh di bawah standar JIPM (=85%). Idle and minor stoppage losses merupakan kerugian terbesar (41,89%), diikuti reduce speed losses (16,42%). Root cause analysis menggunakan fishbone diagram untuk mengidentifikasi akar masalah utama. Usulan perbaikan mencakup penyusunan One Point Lesson (OPL) dan desain UI aplikasi maintenance berbasis digital untuk mendukung monitoring dan pengelolaan perawatan mesin secara terintegrasi.

PT XYZ is a textile company located in Padalarang, West Bandung Regency, West Java. The Continuous Scouring Bleaching (CSB) machine recorded the highest number of breakdowns during the 2025 period, necessitating a Total Productive Maintenance (TPM) analysis. This study aims to assess machine effectiveness through Overall Equipment Effectiveness (OEE), identify the causes of high downtime using the six big losses framework, and formulate improvement proposals. Data were collected through observation, interviews, and company documents for the 2025 period. The average OEE was 49%, with Availability at 82%, Performance at 65%, and Quality yield at 92%, all remaining well below the JIPM standard (=85%). Idle and minor stoppage losses were the largest contributor (41.89%), followed by reduced speed losses (16.42%). Root cause analysis using a fishbone diagram for identified the primary root causes. Proposed improvements include the development of a One Point Lesson (OPL) and the design UI of a digital based maintenance application to support integrated machine monitoring and maintenance management.