Analisis Penerapan Total Productive Maintenance untuk Meningkatkan Efektivitas Mesin Yichang di Section Twisting PT Gajah Tunggal Tbk

Abstract

Mesin Yichang merupakan mesin kritis dalam proses pemintalan di PT Gajah Tunggal Tbk. Selama Maret–Agustus 2025, downtime mesin masih tinggi sehingga efektivitasnya belum optimal. Penelitian ini bertujuan menganalisis penerapan TPM, mengukur keandalan dan efektivitas mesin, mengidentifikasi kerugian dominan, serta menentukan alternatif perbaikan. Metode yang digunakan meliputi TPM, 5S, Reliability Maintenance, OEE, Six Big Losses, Diagram Pareto, dan Fishbone. Hasil menunjukkan MTBF sebesar 633 menit, MTTR 45 menit, MDT 95 menit, dan OEE sebesar 79,38%, masih di bawah standar world class 85%. Kerugian dominan adalah Idle and Minor Stoppage Losses dan Reduced Speed Losses masing-masing 13,38%, serta Breakdown Losses sebesar 6,66%. Perbaikan yang diusulkan meliputi OPL untuk mengatasi penumpukan lint pada jalur benang, pengendalian gangguan kecil, penguatan Autonomous Maintenance, serta peningkatan standar inspeksi dan keterampilan operator.

The Yichang machine is a critical machine in the spinning process at PT Gajah Tunggal Tbk. During March–August 2025, machine downtime remained high, resulting in suboptimal effectiveness. This study aimed to analyze the implementation of Total Productive Maintenance (TPM), measure machine reliability and effectiveness, identify dominant losses, and determine improvement alternatives. The methods included TPM, 5S, Reliability Maintenance, Overall Equipment Effectiveness (OEE), Six Big Losses, Pareto Diagram, and Fishbone Diagram. The results showed an MTBF of 633 minutes, MTTR of 45 minutes, MDT of 95 minutes, and an OEE of 79.38%, below the world-class standard of 85%. The dominant losses were Idle and Minor Stoppage Losses and Reduced Speed Losses, each at 13.38%, followed by Breakdown Losses at 6.66%. The proposed improvements include a One Point Lesson (OPL) to address lint accumulation along the yarn path, control minor stoppages, strengthen Autonomous Maintenance, and improve inspection standards and operator skills.