Penerapan Total Productive Maintenance untuk Meningkatkan Labour Utilization Rate di PT XYZ

Abstract

Pemanfaatan waktu kerja operator pada entry section Continuous Galvalume Line (CGL) PT XYZ belum optimal, ditunjukkan oleh nilai Labour Utilization Rate (LUR) sebesar 60%–68% dan ineffective work sebesar 21%, terutama waiting time. Penelitian ini bertujuan menganalisis penyebab rendahnya LUR dan merancang perbaikan berbasis Total Productive Maintenance (TPM). Data observasi, time study, wawancara, dan historis perusahaan dianalisis menggunakan LUR, Overall Equipment Effectiveness (OEE), Korelasi Pearson, Koefisien Determinasi, Fishbone Diagram, Pairwise Comparison, dan Five Why’s Analysis. Hasil menunjukkan hubungan positif sangat kuat antara LUR dan OEE (r = 0,87), dengan OEE menjelaskan 75,69% variasi LUR. Faktor Method menjadi prioritas utama dengan bobot 0,42. Akar masalahnya adalah belum adanya standardisasi monitoring aktivitas operator. Activity Control Board (ACB), One Point Lesson (OPL), dan Dashboard Digital dirancang untuk mengurangi waktu tidak produktif.

The utilization of operators’ working time at the Entry Section of the Continuous Galvalume Line (CGL) at PT XYZ was not yet optimal, as indicated by a Labour Utilization Rate (LUR) of 60%–68% and an ineffective work proportion of 21%, mainly due to waiting time. This study aimed to analyze the causes of low LUR and develop improvement proposals based on Total Productive Maintenance (TPM). Observation data, time-study results, interviews, and company historical data were analyzed using LUR and Overall Equipment Effectiveness (OEE) calculations, Pearson correlation, coefficient of determination, fishbone diagram, pairwise comparison, and 5 Why’s Analysis. The results showed a very strong positive relationship between LUR and OEE (r = 0.87), with OEE explaining 75.69% of the variation in LUR. The Method factor was identified as the main priority with a weight of 0.42. The root cause was the absence of standardized monitoring of operator activities. An Activity Control Board (ACB), One Point Lesson (OPL), and digital dashboard were designed to reduce unproductive time.