Increased Productivity of Packing Machines Through
Implementation of Total Productive Maintenance Using the Overall Equipment Effectiveness Method Case Study of PT. GFPJ
Ferry Adhi Saputra1*, Mohammad Riza Radyanto2
1,2Industrial Engineering Department, Faculty of Information and Industrial Technology, Universitas Stikubank Semarang
*Corresponding author: ferryadhisaputra@mhs.unisbank.ac.id
Received: August 11, 2023 Approved: September 29, 2023 Abstract
In the world's manufacturing industry, increasing productivity is very important in fulfilling domestic and international markets as well as maintaining customer confidence. The company is trying to increase productivity in production. The fact that the packing machine is in an inefficient condition and the management is trying to implement it. in Total Productive Maintenance (TPM) to maximize the effectiveness of machine facilities in the industry. Then corrective actions are tested using the Overall Equipment Effectiveness (OEE) method, which is the calculation method used in this OEE value is determined by availability, performance and quality. The low OEE value of the packing machine at PT.
GFPJ results from the availability value of = 60% for the results of the performance value of = 100% and the value of quality = 93%, it can be concluded that the OEE value obtained on the machine packing is 59.86%, while the international OEE standard is 87%, so it needs improvement. The factor that becomes a priority for improvement is the performance or performance of the machine in producing concrete, because the performance value is the lowest value of the three factors that affect the OEE value.
Keywords: packing machines, total productive maintenance, overall equipment effectiveness, performance, productivity
Abstrak
Dalam dunia industri manufaktur, peningkatan produktivitas merupakan hal yang sangat penting dalam memenuhi pasar domestik dan internasional juga untuk merawat kepercayaan pelanggan. Perusahaan berusaha untuk meningkatkan produktivitas pada produksi. Diketahui bahwa mesin packing dalam kondisi tidak efisien dan pihak manajemen berusaha untuk menerapkan. dalam Total Productive Maintenance (TPM) untuk memaksimalkan efektivitas fasilitas mesin di industri. Kemudian tindakan perbaikan diuji menggunakan metode Overall Equipment Efectiveness (OEE) adalah metode perhitungan yang digunakan dalam Nilai OEE ini ditentukan oleh availability, performance dan quality. Rendahnya nilai OEE mesin packing pada PT.GFPJ hasil nilai dari availability sebesar = 60% untuk hasil nilai dari Performance sebesar
= 100% dan nilai dari quality sebesar = 93% , maka dapat di simpulkan bahwa nilai OEE yang di dapatkan pada mesin packing yaitu 59,86%, sedangkan untuk standar OEE internasional yaitu 87% sehingga perlu adanya perbaikan. Faktor yang menjadi prioritas perbaikan yaitu performance atau kinerja mesin dalam memproduksi beton, karena nilai Performance merupakan nilai terendah dari tiga faktor yang mempengaruhi nilai OEE.
Kata Kunci: mesin packing, total productive maintenance, overall equipment effectiveness, performance, produktivitas
1. Introduction
In a company, especially in the food industry production activities are the core of a company. In the production system, there is a process of changing raw materials as input into a product as output that has added value and can be sold on the market. In making a product, the role of the machine is needed periodically which can make it easier for humans so that the product produced is in accordance with the plan. Because in carrying out the production process, the main component is a machine [1].
The production process depends on the condition of available resources, such as personnel, machines and other supporting facilities, in order to operate efficiently. The relationship between humans and machines is very important for the smooth production process in a business entity [2]. However, in practice, maintenance or repair efforts often turn out to be a waste, because they do not address the real root of the
problem. This is because maintenance employees do not clearly understand the problems that occur and the factors that cause them [3].
So that it is necessary to analyze the effectiveness of the machine in order to reduce the delay time and determine the effectiveness of the machine using the Overall Equipment Effectiveness (OEE) method.
OEE is the application of the Total Productive Maintenance (TPM) program, the purpose of TPM is to avoid emergency repairs and minimize unscheduled maintenance, where the OEE value obtained is compared to international standard OEE values [4].
Overall Equipment Effectiveness (OEE) is a measure of machine parameters to find out how much the performance of a machine is, the higher the Overall Equipment Effectiveness (OEE) value, the better the machine performance, while the lower the value, the worse the machine performance [5].
The purpose of this study was to determine the percentage value of the performance effectiveness of the packing machine, and to find out the factors that cause the level of effectiveness of the packing machine that is not optimal [6].
2. Material and Methods
The method used in this study is the method of collecting data in this study, namely primary data and secondary data. Primary data is data obtained from direct observation of the company in the form of observations and interviews with production and maintenance management. Secondary data is data that indirectly but in the form of company documentation data, namely production results data, working hours data available on the machine, delay data on the machine, planned downtime data on the machine [7].
To find out the level of effectiveness of a machine, the concept of Total Productive Maintenance (TPM) can be applied, which is a concept used to increase the efficiency of using a machine in order to support total preventive maintenance of a system that involves the participation of all departments and everyone in the company, from the production floor to the top management [8].
The data processing method using OEE is a method for measuring the level of effectiveness in the use of a machine or equipment or system by taking into account several points of view in the measurement process. Meanwhile, OEE itself is defined as a metric that focuses on the effectiveness of an ongoing production operation. The OEE standard value that applies internationally is determined by the Japan Institute of Plant Maintenance (JIPM), which is 85% [9].
The following is an example of calculating Overall Equipment Effectiveness OEE.
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡y = 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒−𝑑𝑜𝑤𝑛𝑡𝑖𝑚𝑒 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚 x100%
Availability is a ratio that indicates the time available to operate the machine. Availability is the comparison between the actual machine operating time and the planned machine operating time [10].
Performance = Output x Cycle Time
𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 x100%
Performance efficiency is the ratio of the quantity of product produced multiplied by its ideal cycle time to the time available for carrying out the production process (operation time) [11].
Quality= 𝑂𝑢𝑡𝑝𝑢𝑡−𝑅𝑒𝑑𝑢𝑐𝑒𝑑−𝑟𝑒𝑤𝑜𝑟𝑘
𝑜𝑢𝑡𝑝𝑢𝑡 x100%
Quality Ratio Is a ratio that describes the ability of equipment to produce goods. This stage aims to analyze the quality of products according to standards. With the following formula: [12]
OEE = Availability % x Performance efficiency % x Rate of quality product %
OEE (Overall Equipment Effectiveness) is part of Total Productive Maintenance, which is a productivity ratio consisting of three aspects, namely availability, performance and quality [13].
3. Calculation Method
This calculation is done by making direct observations to find out the operating conditions of the packing machine, knowing things related to OEE. In addition, brainstorming was also carried out with
machine operators to better understand the problems that occur in the operation of packing machines. In addition to direct observation and brainstorming with machine operators, literature studies were also carried out to assist in the process of calculating OEE values, starting from what must be considered in OEE calculations, calculating machine availability values, performance ratios and quality ratios from packing machine operators.
The method of data collection and calculation of OEE on packing machines has not reached the company's target for an OEE packing value of 87%, while the results of calculating the OEE value are still below the company's standard. This means that the OEE value on the packaging machine does not meet the standard OEE value set by the company.
The OEE calculation factor, the factors that make the delay time on the packing machine are the waiting time for wip, roll change, shift end cleaning and machine settings by the operator. This is caused by several factors, namely limited operator skills, lack of equipment to support the production process, and lack of training and support for packing machine operators for packing machines.
4. Results and Discussion
After obtaining the loading time value for each month, then calculating the required operation time to calculate availability, operating time is the production time without considering the downtime that occurs, so to calculate the operation time: obtained using the equation for two months, namely August and September (2022) [14].
Tabel 1. Availability Ratio August – September 2022
August Downtime
(minute)
Operating time (minute)
Failure & repair (minute)
Setup & adj (minute)
Availability
Week 1 142 338.17 153.86 6 73%
Week 2 220 260.50 247.71 8.33 54%
Week 3 182 298.17 189.56 9.167 62%
Week 4 227 253.50 243.50 11.5 53%
Week 5 213 267.00 229.78 10 55.18%
Amount 984 146774 106441 44.9 297%
Tabel 2. Availability Ratio August – September 2022 September Downtime
(minute)
Operating time (minute)
Failure & repair (minute)
Setup & adj (minute)
Availability
Week 1 173 311.86 189.91 10 59%
Week 2 177 302.80 194.70 7 63%
Amount 350 614.66 384.61 17 122%
Based on the calculation results in Table 1 and Table 2, the availability value of the packing machine is below the applicable international standard value. The international standard for availability is ≥90%
while the actual average yield of packing machines is 60%
Performance ratio is a ratio that shows the ability of equipment to produce goods. Calculation of the performance ratio value requires some data, namely output, operating time, and ideal cycle time: obtained using the equation for two months, namely August and September (2022) [15].
Tabel 3. Performance ratio ratio August – September 2022
August Operating time
(minute)
Output (minute)
Ideal cycle time (minute)
Performance ratio
Week 1 338.17 23.7047 0.75 100%
Week 2 260.50 18.2047 11.57 100&
Week 3 298.17 18.8747 1.08 92%
Week 4 253.50 17.7047 0.36 100%
Week 5 329.00 20.3747 0.67 89%
Amount 1279.33 98.8635 14.43 481%
Tabel 4. Performance Ratio Agustus – September 2022 September Operating time
(minute)
Output (minute)
Ideal cycle time (minute)
Performance ratio
Week 1 311.86 21.2433 0.85 119%
Week 2 302.80 21.1747 0.86 100%
Amount 614.66 42.41797 1.70 219%
The results of the performance ratio calculation can be seen in Table 3 and Table 4 shows that the performance ratio value of the packing machine is already above the JIPM international standard.
International standards for performance ratio, which is ≥95%. While the performance ratio value is 100%
Rate of Quality Product is a ratio that shows the ability of equipment to produce goods in good condition. Rate of Quality Product is calculated using the equation. The results of the Rate of Quality Product calculation can be seen in Table 5 - 6 below.
Tabel 5. Quality Ratio August - September 2022
August Output
(minute)
Net operating time (minute)
Value operating time (minute)
Quality ratio
Week 1 23.7047 338.68 337.00 100%
Week 2 18.2047 260.07 258.43 99&
Week 3 18.8747 269.64 268.00 55%
Week 4 17.7047 252.92 251.29 99%
Week 5 20.3747 291.07 289.43 99%
Amount 98.8635 1412.32 1406.56 454%
Tabel 6. Quality Ratio August - September 2022 September Output
(minute)
Net operating time (minute)
Value operating time (minute)
Quality ratio
Week 1 21.2433 303.48 305.69 101%
Week 2 21.1747 302.17 300.85 99%
Amount 42.41797 605.64 606.54 200%
Shows that the Rate of Quality Product value of the packing machine is below the international standard value set by JIPM. The international standard for Rate of Quality Product is ≥99%. While the Rate of Quality Product value of the packing machine is 93%. The results of the calculation of Overall Equipment Effectiveness (OEE) can be seen in Table 7 and Table 8.
Tabel 7. OEE Value for August - September 2022
August Availability rate Performance Rate Quality Ratio OEE
Week 1 70% 100% 100% 70.31%
Week 2 54% 100% 99% 53.84%
Week 3 62% 92% 99% 55.83%
Week 4 53% 100% 99% 52.35%
Week 5 69% 89% 99% 60.30%
Amount 308% 481% 497% 292.63%
Tabel 8. OEE Value for August - September 2022
September Availability rate Performance Rate Quality Ratio OEE
Week 1 59% 119% 101% 63.69%
Week 2 63% 100% 99% 62.68%
Amount 122% 219% 200% 126.36%
Based on the calculation results in Table 7 and Table 8, it shows that the OEE value on the packing machine is below the international standard value set by JIPM. The international standard for OEE, which is ≥875%. While the OEE value on the packing machine is 59.86%.
5. Conclusion
There are 3 elements of OEE, namely availability ratio, performance ratio and quality ratio. The following is the availability after the calculations have been carried out and on average, corrective actions have been carried out starting from August to September 2022.
Based on the results of the research that has been done, it can be concluded that by applying the OEE method to the measurement of the effectiveness performance of the packing machine can determine the Availability Ratio value of 60%, Performance Ratio of 100%, Quality Ratio of 93%. Then the Overall Equipment Effectiveness (OEE) value is obtained, which is 59.86%. So that the Overall Equipment Effectiveness (OEE) value is still below the international standard of 87% so that it is necessary to improve and increase OEE on the packing machine.
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