Total productive maintenance policy to increase effectiveness and maintenance performance using overall equipment effectiveness

Abstract

In the manufacturing process, the machine is very important because downtime can inhibit and even stop production. We focused on the highest downtime that occurred in a particular product line and critical machine. This research contributes to overcoming and making the machine's performance and ability better. We make use the Total Productive Maintenance (TPM), which started by calculating Overall Equipment Effectiveness (OEE) and Six Big Losses. This study also provides the maintenance attempt to increase the effectiveness and to eliminate losses incurred by calculating Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR). Finally, we proposed the TPM implementation to improve the effectiveness of the machine. The result showed that the OEE has not reached the ideal value due to the low availability. Breakdown losses contributed to the biggest factor in the loss. The way to overcome the cause of breakdown losses is to increase performance maintenance, by calculating and evaluating MTBF and MTTR. This research presented the cause of the low value of OEE, provided the performance maintenance policy according to MTBF and MTTR, and proposed the TPM implementation.

Keywords

• total productive maintenance
• overall equipment effectiveness
• six big losses
• mean time between failure
• mean time to repair