Abstract :

 In the midst of production process to fulfilling the needs of n2 vaccine, several problems occur and cause the production process to be hampered. The high frequency of breakdowns that occurred became problems that results in longer production process and some products become rejected and cannot be absorbed as a whole to meet the production needs. Preventive maintenance that have been conducted so far are considered not optimal because there are more breakdown maintenance than preventive maintenance. History of the breakdown shows that 35% of the total number of production batches experiences failure of the machine in the production process experiences failure of the production process. The results of the study using quantitative analysis show that the OEE of the integrated Filling Machine is only 55%, far below the ideal OEE standard of 95%. A qualitative analysis also conducted to further explores the cause of the bottlenecks in the production process which involves the production and maintenance unit.

Study and analyses are conducted to find the root cause of high disturbances that results in losses and obstacle to production process. By using current reality tree, found that the main cause of the bottleneck in the production process on the high number of the breakdown in the Integrated Filling Machine is lack in maintenance activity which the preventive maintenance that conducted doesn’t have clear procedure then coupled with the maintenance team’s habit that prefer to work in breakdown maintenance than preventive maintenance.

To solve the problem three alternative solutions are prepared to be choose. The alternative solutions are Autonomous Maintenance, Planned Maintenance, and Principal’s service agreement. All of the alternative solution is selected with consideration of production needs with their respected advantages and disadvantages. Of the three alternative solutions provided, Analytical Hierarchy process will be conducted to determine which alternative is more likely to be implemented. Planned maintenance was chosen as the best solution that meet the needs of each stakeholder with the most mitigable risks and has advantages that can solve the problems that occur.

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Keywords :

analytical hierarchy process, Integrated Filling Machine, n2 Vaccine Production, Overall Equipment Effectiveness, Planned maintenance

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