Designing Lean Maintenance Using Total Productive Maintenance Method – A Case Study at Wiring Harness Production

Abstract

Consumer demand for 4-wheeled and 2-wheeled motorized vehicles in Indonesia is increasing yearly. In 2022, car sales increased by 18.1%. At the same time, motorcycle sales increased by 3.24%. Automotive companies will compete with each other to meet the needs of consumers in the future. This is also true for automotive parts suppliers. PT XYZ is a company that supplies wiring harnesses for the needs of motorized vehicle components. Currently, the company is facing a problem with overtime of up to 4 hours in several production lines. The company missed the production target because the production plan had not considered any waste that happened on the production floor. Downtime of machines can stop production on the line. Downtime can occur due to machine failure. The company must choose the proper steps for resolution. If waste continues to be ignored, the company will struggle to compete with its competitors. This research aims to solve the waste problem through the Total Productive Maintenance (TPM) Method. Several steps are used to solve the problem: root cause analysis, determining the TPM pillars applied, RCM, and realization of TPM pillars. The research results are lean maintenance design from completing TPM pillars, such as autonomous maintenance, planned maintenance, and development management.