Usulan Perbaikan Pemeliharaan Mesin untuk Mereduksi Downtime dengan Penerapan Total Productive Maintenance (TPM) Pada Mesin D300

Abstract

Abstract. PT Remaja Rosdakarya is a publisher and printing company of books and magazine. The books are printed every day, where one of them using the D300 machine. The company has implemented scheduled maintenance of D300 machine with interval of 8 hours, 40 hours, 160 hours and 1250 hours. However, the D300 machine has corrective maintenance 22 times with a downtime of 195 hours. The Overall Equipment Effectiveness (OEE) of D300 machine is 84.03%. Based on calculations, the largest loss is the breakdown loss with a percentage of 6.23%. The main cause of the breakdown is that the gear wheel component has been damaged 8 times with total downtime of 24 hours for a year, the Mean Time to Failure (MTTF) of 464.67 hours with reliability level of 6.53% and the Mean Time to Repair (MTTR) of 3.74 hours. The autonomous maintenance pillar is used to propose visual control to increase the availability from 84.75% to 88.55%. This study also adopt preventive maintenance by planning the maintenance schedule of component maintenance. The result is that the gear wheel component should be maintained every 34 hours, in order to get reliability of 90%. It will increase OEE from 84,03% to 88.30%.

Keywords: Overall Equipment Effectiveness (OEE), autonomous maintenance, preventive maintenance.

Abstrak. PT Remaja Rosdakarya adalah penerbit dan perusahaan percetakan buku dan majalah. Buku-buku dicetak setiap hari, di mana salah satunya menggunakan mesin D300. Perusahaan telah menerapkan pemeliharaan terjadwal terhadap mesin D300 dengan interval 8 jam, 40 jam, 160 jam, dan 1250 jam. Namun, mesin D300 mengalami perawatan korektif 22 kali dengan downtime 195 jam. Overall Equipment Effectiveness (OEE) mesin D300 adalah 84,03%. Berdasarkan perhitungan, loss terbesar adalah breakdown loss sebesar 6,23%. Penyebab utama kerusakan adalah bahwa komponen gear wheel telah rusak 8 kali dengan total downtime 24 jam selama setahun, Mean Time to Failure (MTTF) 464,67 jam dengan tingkat keandalan 6,53% dan Mean Time to Repair (MTTR) selama 3,74 jam. Pilar autonomous maintenance digunakan untuk mengusulkan kontrol visual supaya availability meningkat dari 84,75% menjadi 88,55%. Penelitian ini juga mengadopsi preventive maintenance dengan merencanakan jadwal perawatan pemeliharaan komponen. Hasilnya adalah bahwa komponen gear wheel harus dijaga setiap 34 jam, agar bisa mencapai reliability sebesar 90%. Hal ini akan meningkatkan OEE dari 84,03% menjadi 88,30%.

Kata kunci: Overall Equipment Effectiveness (OEE), autonomous maintenance, preventive maintenance.