Penerapan TPM untuk Mengatasi Downtime dan Meningkatkan Kinerja Mesin Solna D 380 di PT Yudhistira Ghalia Indonesia

Abstract

Penelitian ini menganalisis penerapan Total Productive Maintenance (TPM) untuk mengurangi downtime pada mesin Solna D 380 di PT Yudhistira Ghalia Indonesia. Metode penelitian menggabungkan pendekatan kualitatif dan kuantitatif melalui observasi lapangan, wawancara, dan studi literatur. Hasil analisis menunjukkan nilai Overall Equipment Effectiveness (OEE) mesin rata-rata hanya mencapai 22-29%, jauh di bawah standar ideal 85%, dengan availability 61-69% dan performance 40-52% sebagai faktor penentu utama. Analisis six big losses mengungkapkan idling and minor stoppage losses 44% dan reduced speed losses 29% sebagai penyumbang terbesar downtime. Dengan menggunakan fishbone diagram dan Failure Mode and Effect Analysis (FMEA), penelitian berhasil mengidentifikasi tiga akar masalah utama: tidak dilakukannya pengecekan mesin rutin RPN 211,98, gagal splicing RPN 196,79, dan gripper tidak menjepit RPN 194,95. Sebagai solusi, penelitian merekomendasikan implementasi checksheet dan One Point Lesson (OPL) sebagai media edukasi dan standarisasi prosedur kerja kepada operator. Temuan penelitian ini dapat memberikan kontribusi penting dalam meningkatkan efisiensi produksi melalui pendekatan TPM yang terstruktur.

This research analyzes the application of Total Productive Maintenance (TPM) to reduce downtime on the Solna D 380 machine at PT Yudhistira Ghalia Indonesia. The research method combines qualitative and quantitative approaches through field observations, interviews, and literature studies. The results of the analysis showed that the average machine Overall Equipment Effectiveness (OEE) value only reached 22-29%, far below the ideal standard of 85%, with availability 61-69% and performance 40-52% as the main determining factors. Six big losses analysis revealed idling and minor stoppage losses of 44% and reduced speed losses of 29% as the biggest contributors to downtime. Using fishbone diagrams and Failure Mode and Effect Analysis (FMEA), the research identified three main root causes: not performing routine machine checks RPN 211.98, splicing failure RPN 196.79, and gripper not clamping RPN 194.95. As a solution, the study recommends the implementation of checksheets and One Point Lesson (OPL) as a medium of education and standardization of work procedures to operators. The findings of this research can make an important contribution in improving production efficiency through a structured TPM approach.