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Nazaruddin1 IMPLEMENTASI TOTAL PRODUCTIVITY MAINTENANCE (TPM) Nazaruddin.

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Presentasi berjudul: "Nazaruddin1 IMPLEMENTASI TOTAL PRODUCTIVITY MAINTENANCE (TPM) Nazaruddin."— Transcript presentasi:

1 Nazaruddin1 IMPLEMENTASI TOTAL PRODUCTIVITY MAINTENANCE (TPM) Nazaruddin

2 Kebijakan keuangan UGM 2 Ada 2 metode pengukuran produktivitas (Sumanth, 1984): 1. Productivity Management; proses manajemen formal yg menyertakan semua tingkatan manajemen dan kartyawan dengan sasaran akahir mengurangi ongkos pabrikasi, distribusi dan penjualan suatu produk/jasa melalui suatu pengintegrasian empat tahap siklus produktivitas (MEPI) 2. Productivity Engineering; terkait dengan disain, pemeliharaan dan pengembangan pengukuran produktivitas, evaluasi, perencanaan, dan sistem peningkatan dalam organisasi pabrikasi dan jasa

3 Nazaruddin3 Nakajima (1988); productivity engineering ≈ Total Productivity Maintenance melalui pengukuran Overall Equipments Effectiveness (OEE) W. Mark & M. Nakamura (1997); “ TPM is an activity/partnership between maintennace and production organisations to improve product quality, reduce waste, reduce manufacturing cost, increase equipment availability and improve a company’s overall state of maintenance”

4 Nazaruddin4 Loading time Downtime Losses Net Operating Time Speed Losses Valuable Operating Time Defect Losses 1.Equipment Failure 2. Setup & Adjustment 3. Idling & Minor Stoppages 4. Reduced Speed 5. Defects in Process 6. Reduced Yield MTBF Availability = -------------------------------- MTBF + MTTR + MWT (Total Pieces/Operating Time) Performance = ------------------------------------------ Efficiency Theoritical O/T Processed amount – Defect amount Rate of Quality = --------------------------------------- Products Processed amount EquipmentsSix Big Losses Calculation of Overall Equipments Effectiveness OVERALL EQUIPMENTS EFFECTIVENESS = Availability x Performance Eff x Rate of Quality

5 Nazaruddin5 Ket: MTBF : Mean Time Between Failure (expectation of production time between failures) MTTR : Mean Time To Repair (expectation of time to restoration) MWT : Mean Waiting Time (expectation of time for restoration to statr) OVERALL EQUIPMENTS EFFECTIVENESS (OEE) = Availability x Performance x Rate of Quality Avaibility; pengukuran kehandalan mesin yang diukur dari waktu terbuang (downtime loss) pada Saat mesin utama sedang beroperasi, sedangkan Performance Efficiency Mengukur ouput selama waktu yang tersedia (actual cycle time) dibandingkan dengan kapasitas terpasang (theoretical cycle time) dan Quality Rate mengukur tingkat ouput produk bagus dibandingkan dengan jumlah produk gagal

6 Nazaruddin6 Six Big Loss Category OEE Loss Category Event Equipment failureDown Time Loss Tool failure Unplanned maintenance General breakdown Equipment failure Setup and Adjustment Downt Time Loss Change over falvour or size Material shortages Operator shortages Warm up time Idling & Minor Stoppage Reduced Speed Speed Loss Obstructed product flow Component jams Misfeeds Sensor blocked Delivery blocked Cleaning/checking Rough running Under capacity Under design Equipment wear Operator inefficiency Defects in Process Reduced Yield Quality Loss Scrap Rework In-Process damage In-Process expiration Incorrect assembly

7 Nazaruddin7 Contoh Aplikasi: PT. CP merupakan salah satu produsen pakan ternak yang memproduksi makanan ternak untuk ikan. Aliran proses produksi dapat dilihat pada diagram berikut ini. Raw Material Coarse Grinding Dry Mixing Fine Grinding Wet Mixing Finish Goods PackagingCooling Pelletizing (sinking feed) Finish Goods PackagingcoolingDrying Extrution (floating feed)

8 Nazaruddin8 MesinTipetahunKap. Terpasang (t/h) Melayani produk Coarse Grinding A Horisontal19808S & F Coarse Grinding A Horisontal198010S & F Fine Grinding 2Horisontal19874,5F Fine Grinding 3Horisontal19874,5F Fine Grinding 4Horisontal19874,5S Fine Grinding 5Horisontal19874,5S Mixer 1Ribbon198050S & F Mixer 2Ribbon198016S & F Pellet Mill 1Double Roller19802.5S Pellet Mill 2Double Roller19802.5S Pellet Mill 3Double Roller19904S Extruder 1Screw Press19973F Extruder 2Screw Press20024F

9 Nazaruddin9 Mesin Pellet 1 Kapasitas =2.5T/jam Jam Kerja/hari =22Jam Bulan Pellet 1, Kapasitas = 2,5 T/jam H KerjaJam TersediaProduksiProd/hariT/jam% Capaian Januari194181088 572.6104 Februari194181088 572.6104 Maret265721451 562.5101 April265721362 522.495 Mei265721327 512.393 Juni275941441 532.497 Juli255501334 532.497 Agustus255501251 502.391 September255501332 532.497 Oktober17374722 421.977 Nopember235061020 442.081 Desember204401071 542.497 Total278611614487 522.495 Kapasitas pakan tenggelam (sinking) berdasarkan kapasitas Mesin Pellet Mill Kapasitas pakan terapung (floating) berdasarkan kapasitas Mesin Extruder Data produksi tahun 2006 untuk Mesin Pellet 1 adalah sbb:

10 Nazaruddin10 Lakukan analisis terhadap TPM Mesin Pellet tersebut (data tambahan) URAIAN Pellet Mill 1 Total JanFebMarAprMeijunJulAgstSepOktNopDes Production (t)1088 14511362132714411334125113327221020107114487 Work Day19 26 2725 172320278 Plan Prod. Hours418 572 594550 3745064406116 MTBF3383745165154604864974884973384583455312 MTTR (h)126.44.862010.82.83.532226.399.6 MWT (h)2148.670.4110.184.9125.5128.2104.553.740.1111.558.9957.4 Operating Time406411.6567.2566552583.2547.2546.5547372504413.7 6016. 4 Net Time385363496.8455.9467.1457.7419442493.3331.9392.5354.85059 Theoritical C/T (t/h)2.5 Actual C/T (t/h)2.6 2.52.42.32.4 2.32.41.92.02.4 Blocked Feed (t)31.82714.915.427.738.436.341.220.98.614.516.7293.4 Rejects (t)41.829.341.520.840.932.830.229.332.934.135.743.9413.2

11 Nazaruddin11 See you next time


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