Minimasi Durasi Lost Time Machine dengan Penerapan Total Productive Maintenance Pada Departemen Converting di PT XYZ

Abstract

Penelitian ini bertujuan untuk mengidentifikasi penyebab rendahnya nilai Overall Equipment Effectiveness (OEE), menganalisis akar masalah lost time, serta merancang perbaikan berbasis Total Productive Maintenance (TPM) pada mesin Cut size sheeter Will 4 di Departemen Converting PT XYZ. Metode yang digunakan meliputi perhitungan OEE, analisis Six Big Losses dan perhitungan Reliability Maintenance. Berlandaskan hasil analisis periode Agustus 2025–Januari 2026 menunjukkan rata-rata OEE sebesar 57,91% yang masih di bawah standar 85%. Melalui analisis Six Big Losses ditemukan kerugian dominan berasal dari reduce speed losses (25%), diikuti equipment losses (13%) dan idling & minor stoppage losses (11%). Akar masalah utama ditemukan meliputi ketidaktepatan setting mesin, tidak adanya standar penyambungan belt, serta belum tersedianya instruksi kerja. Implementasi perbaikan dilakukan melalui penerapan One Point Lesson (OPL), instruksi kerja, serta tools seperti Cleaning Map dan Defect Map. Upaya implementasi ini berhasil menurunkan lost time sebesar 10,29% dan meningkatkan Overall Equipment Effectiveness sebesar 4,34%.

This study aims to identify the causes of the low Overall Equipment Effectiveness (OEE) value, analyze the root causes of lost time, and develop improvement proposals based on Total Productive Maintenance (TPM) for the Will 4 Cut size sheeter machine in the Converting Department of PT XYZ. The methods employed in this study include OEE calculation, Six Big Losses analysis and Reliability Maintenance calculation. The analysis results for the period of August 2025 to January 2026 indicate that the average OEE value was 57,91%, which is still below the standard target of 85%. The dominant losses were caused by reduce speed losses (25%), followed by equipment losses (13%) and idling and minor stoppage losses (11%). The main root causes identified include inaccurate machine settings, the absence of standardized belt splicing procedures, and the lack of work instructions. The proposed improvements were implemented through the application of One Point Lessons (OPL), work instructions, and supporting tools such as cleaning maps and defect maps. These improvement efforts successfully reduced machine lost time by 10.29% and enhanced Overall Equipment Effectiveness by 4.34%.