IMPLEMENTASI TOTAL PRODUCTIVITY MAINTENANCE (TPM) Nazaruddin Nazaruddin

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 Kebijakan keuangan UGM

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” Nazaruddin

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

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 Nazaruddin

Nazaruddin Six Big Loss Category OEE Loss Event Equipment failure Down Time Loss Tool failure Unplanned maintenance General breakdown 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 Nazaruddin

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 Packaging Cooling Pelletizing (sinking feed) Finish Goods Packaging cooling Drying Extrution (floating feed) Nazaruddin

Mesin Tipe tahun Kap. Terpasang (t/h) Melayani produk Coarse Grinding A Horisontal 1980 8 S & F 10 Fine Grinding 2 1987 4,5 F Fine Grinding 3 Fine Grinding 4 S Fine Grinding 5 Mixer 1 Ribbon 50 Mixer 2 16 Pellet Mill 1 Double Roller 2.5 Pellet Mill 2 Pellet Mill 3 1990 4 Extruder 1 Screw Press 1997 3 Extruder 2 2002 Nazaruddin

Pellet 1, Kapasitas = 2,5 T/jam Kapasitas pakan tenggelam (sinking) berdasarkan kapasitas Mesin Pellet Mill Kapasitas pakan terapung (floating) berdasarkan kapasitas Mesin Extruder Mesin Pellet 1 Kapasitas = 2.5 T/jam Jam Kerja/hari = 22 Jam Bulan Pellet 1, Kapasitas = 2,5 T/jam H Kerja Jam Tersedia Produksi Prod/hari % Capaian Januari 19 418 1088 57 2.6 104 Februari Maret 26 572 1451 56 101 April 1362 52 2.4 95 Mei 1327 51 2.3 93 Juni 27 594 1441 53 97 Juli 25 550 1334 Agustus 1251 50 91 September 1332 Oktober 17 374 722 42 1.9 77 Nopember 23 506 1020 44 2.0 81 Desember 20 440 1071 54 Total 278 6116 14487 Data produksi tahun 2006 untuk Mesin Pellet 1 adalah sbb: Nazaruddin

Lakukan analisis terhadap TPM Mesin Pellet tersebut (data tambahan) URAIAN Pellet Mill 1 Total Jan Feb Mar Apr Mei jun Jul Agst Sep Okt Nop Des Production (t) 1088 1451 1362 1327 1441 1334 1251 1332 722 1020 1071 14487 Work Day 19 26 27 25 17 23 20 278 Plan Prod. Hours 418 572 594 550 374 506 440 6116 MTBF 338 516 515 460 486 497 488 458 345 5312 MTTR (h) 12 6.4 4.8 6 10.8 2.8 3.5 3 2 26.3 99.6 MWT (h) 21 48.6 70.4 110.1 84.9 125.5 128.2 104.5 53.7 40.1 111.5 58.9 957.4 Operating Time 406 411.6 567.2 566 552 583.2 547.2 546.5 547 372 504 413.7 6016.4 Net Time 385 363 496.8 455.9 467.1 457.7 419 442 493.3 331.9 392.5 354.8 5059 Theoritical C/T (t/h) 2.5 Actual C/T (t/h) 2.6 2.4 2.3 1.9 2.0 Blocked Feed (t) 31.8 14.9 15.4 27.7 38.4 36.3 41.2 20.9 8.6 14.5 16.7 293.4 Rejects (t) 41.8 29.3 41.5 20.8 40.9 32.8 30.2 32.9 34.1 35.7 43.9 413.2 Nazaruddin

See you next time Nazaruddin