Penerapan Total Productive Maintenance Pada Lini Produksi Section Solid di PT XYZ

Abstract

Penurunan efektivitas mesin akibat tingginya downtime berdampak pada rendahnya produktivitas. Studi ini menganalisis penerapan Total Productive Maintenance (TPM) pada lini produksi Section Solid di PT XYZ, khususnya mesin Kikusui 36 HUK-ACW. Metode yang digunakan mencakup analisis delapan pilar TPM, budaya kerja 5S, perhitungan OEE, analisis keandalan mesin (MTBF, MTTR, MDT), serta identifikasi akar masalah dengan diagram fishbone. Rata-rata nilai OEE sebesar 81%, dengan Availability dan Quality sesuai standar, namun Performance masih rendah. Masalah utama berasal dari kerusakan punch/die, motor, dan gearbox. Untuk mengatasinya, diterapkan One Point Lesson (OPL) guna meningkatkan pemahaman teknis operator. Penerapan TPM secara menyeluruh terbukti efektif dalam meningkatkan keandalan mesin dan efisiensi produksi.

A decline in machine effectiveness due to high downtime often leads to reduced productivity. This study analyzes the implementation of Total Productive Maintenance (TPM) on the Section Solid production line at PT XYZ, focusing on the Kikusui 36 HUK-ACW machine. The methods include analysis of the eight TPM pillars, 5S practices, OEE calculation, reliability metrics (MTBF, MTTR, MDT), and root cause identification using a fishbone diagram. The average OEE was 81%, with Availability and Quality meeting standards, while Performance lagged. Key issues involved failures in punch/die components, motors, and gearboxes. To address these, One Point Lessons (OPL) were introduced to enhance operators’ technical understanding. The comprehensive TPM approach proved effective in improving machine reliability and production efficiency.