Articles

Total Productive Maintenance Strategy to Increase Overall Equipment Effectiveness of Integrated Filling Machine N2 Vaccine Production Pt. Xyz

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 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.

Total Productive Maintenance Analysis on Printing Machine (A Case Study in an Indonesian Flexible Packaging Manufacturer)

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PT XYZ is one of Indonesia’s major flexible packaging manufacturer companies. The company suffers losses from the increase in printing machine breakdown from 1.65% in 2019 to 2.52% in 2021. This paper aims to reduce the breakdown duration in 2022 by identifying and solving the root cause by implementing one of the alternative solutions. The primary data are collected via a series of interviews and from the company’s manufacturing reports. Using Current Reality Tree (CRT) the root cause was identified as a lack of regular maintenance evaluation and improvement. The study proposes three alternative solutions: Planned Maintenance (PM), Autonomous Maintenance (AM), and condition-based maintenance using IoT sensors. In determining the preferred alternative, the study uses Analytic Hierarchy Process (AHP) with five criteria: OEE improvement, human capital improvement, Capex required, Opex required, and ease of implementation. Align with the AHP result, the company agreed to implement Planned Maintenance (PM). After the first two months of implementation, the average year-to-date breakdown in 2022 was reduced to 2.29%.