Implementation of Total Productive Maintenance (TPM) on Mitsui Seiki Compressors to Reduce Production Downtime

PT XYZ is one of the companies engaged in the precast concrete manufacturing industry which is specially designed to meet the needs of industrial markets such as high-quality building and building construction. The machine under study is the machine used for assembling the spun pile reinforcement frame in the rotary workshop. The purpose of this study is to analyze the application of Total Productive Maintenance (TPM) through the effectiveness and efficiency of heading machine performance and analyze the factors that affect the Overall Equipment Effectiveness (OEE) value and present a proposed heading machine maintenance strategy. The method used is OEE with Six Big Losses analysis. For the analysis of the six big losses on the OEE value, namely the value of Idle and minor stoppage (a decrease due to many machine stops) which is a factor that has the largest percentage of the six big losses with a resulting factor value of 7.0%. Then followed by reduced speed losses (decrease in engine speed) of 3.96% and then deffect losses of 3.48% and the three other factor values, namely breakdown losses, setup losses, and yield losses. Measurement of the level of effectiveness and efficiency of the heading machine at PT XYZ using the OEE method for the period 2022 in January - December obtained an average value of 78.28%. The resulting value is still far from the ideal OEE standard value of 85% which refers to the world class standard. The lowest OEE factor value is obtained from the calculation of Performance Efficiency of 86.29% where it is necessary to update the machine maintenance scheduling so as to increase the efficiency of the heading machine performance that supports the production speed of the company.

This study aims to improve the effectiveness of ampoule filling machines in a pharmaceutical manufacturing company through the implementation of Total Productive Maintenance (TPM) supported by Overall Equipment Effectiveness (OEE) evaluation. The study was motivated by a decline in machine performance during the period from January to August 2024, characterized by low production output, high downtime, and high defect rates. A quantitative research approach was employed using primary and secondary data collected from 30 production batches through field observations, interviews, and documentation review. Machine effectiveness was evaluated using OEE, which consists of availability, performance, and quality components, while efficiency losses were identified using the Six Big Lossesframework. Root causes were analyzed using a Fishbone diagram, and improvement actions were formulated based on relevant TPM pillars. The results show that the initial average OEE value was 56%, significantly below the world-class benchmark of 85%, with breakdown losses and quality defect losses identified as the dominant contributors to inefficiency. After implementing TPM-based improvements—specifically the replacement and recalibration of malfunctioning swing conveyor sensors and the redesign of the ampoule outfeed system—the average OEE value increased to 71.9%. Improvements were also observed in the OEE components, with availability increasing to 86.5%, performance to 92.0%, and quality to 90.5%. These results indicate a substantial reduction in downtime and defect rates. The study confirms that the integration of TPM and OEE is effective in enhancing machine effectiveness and production efficiency in sterile pharmaceutical manufacturing.

The application of Total Productive Maintenance (TPM) using the Overall Equipment Effectiveness (OEE) method at PT. DEF, The issue of maintenance has become crucial as it affects not only the reliability of the machines but also the speed and quality of production. This study will explore how the implementation of TPM using the OEE approach can improve machine effectiveness in a production environment, with a focus on timely and optimal maintenance strategies.The research aimed to assess the efficiency and effectiveness of machine operations, particularly injection molding machines, within the company's production line. Through the collection and processing of operational data, it was found that the OEE value for the machines in question ranged from 94% to 95%, surpassing the company's set standard of 93%. The high OEE score reflects effective machine utilization, availability, performance, and quality rates. The research highlights that while the current system meets international standards for machine maintenance, continuous improvements can further optimize machine productivity and reduce downtime. Keywords: Injection, Molding, OEE, TPM

Overall Equipment Effectiveness (OEE) evaluates quantitatively how effectively a manufacturing operation is utilised. Total Productive Maintenance (TPM) was considered by Tibaldi, a leading food manufacturer in Australia for achieving OEE. This research project has identified performance gaps, developed plan and implemented it in Thermoforming area of the business. The developed methodology helped Tibaldi in improving productivity and quality through TPM involving machines, equipment, processes, and employees. This paper demonstrates how this can be achieved by reducing lead time and establishing lean environment. Productivity improvement through the devised methodology led to further enhancement of competitiveness of the organisation for domestic and international markets of processed food manufactured by Tibaldi Australia. Lessons learned from application of TPM in Thermoforming, a key asset area, is rolled out to other sections of the plat and results from this pilot study are presented in this paper.

This study aims to analyze the application of Total Productive Maintenance (TPM) on the Steam Boiler machine at PG. XYZ, which plays an important role in the sugar production process. The background of this research is the increasing downtime of the boiler machine, which was recorded at 15.67 hours in 2023 and jumped to 29.76 hours in 2024. The method used is Overall Equipment Effectiveness (OEE) analysis with data collection through observation and interviews on data during the period May - September 2023 and 2024. The research findings show that the highest OEE value reached 97.57% in September 2023, while the lowest value was recorded as 79.88% in August 2024, with an average OEE of 86.98%. Although the Availability value reached 99.26%, the Performance and Quality values were still below World Class standards. The conclusion of this study emphasizes the importance of effective maintenance to improve machine performance and productivity, as well as the need for continuous improvement strategies in the maintenance process.

Learning curve analysis in total productive maintenance

<div><p><em>This study aims to examine and analyze the impact of work attitude, Total Productive Maintenance (TPM) on the Overall Equipment Effectiveness (OEE) and production continuity and the other effect of Work Attitude and Total Productive Maintenance (TPM) on production continuity: The mediating role of Overall Equipment Effectiveness (OEE). The research was conducted at PT. Semen Tonasa i.e. units II to V unit which is the largest cement producer in eastern Indonesia. Withdrawal of respondents did with the criteria that only respondents yang having their respective sectors and who have work experience of at least one year were used as samples. Results of analysis Partial Least Square (PLS) Version 2.0.M3 used in analyzing the contribution of exogenous variables on endogenous variables directly, Sobel Test was used for pushing analyze the contribution of the indirect effect (mediation) whereas importance- performance analysis (IPA) to analogous interpret the relationship loading factor value and the average value. The results of this study provide evidence of work attitude has a positive and significant effect on the overall equipment effectiveness (OEE), total productive maintenance (TPM) has a positive and significant effect on overall equipment effectiveness (OEE), work attitude, total productive maintenance (TPM) and overall equipment effectiveness (OEE) positive and significant impact on production continuity.</em></p></div>

This study aims to examine and analyze the impact of work attitude, Total Productive Maintenance (TPM) on the Overall Equipment Effectiveness (OEE) and production continuity and the other effect of Work Attitude and Total Productive Maintenance (TPM) on production continuity: The mediating role of Overall Equipment Effectiveness (OEE). The research was conducted at PT. Semen Tonasa i.e. units II to V unit which is the largest cement producer in eastern Indonesia. Withdrawal of respondents did with the criteria that only respondents yang having their respective sectors and who have work experience of at least one year were used as samples. Results of analysis Partial Least Square (PLS) Version 2.0.M3 used in analyzing the contribution of exogenous variables on endogenous variables directly, Sobel Test was used for pushing analyze the contribution of the indirect effect (mediation) whereas importance- performance analysis (IPA) to analogous interpret the relationship loading factor value and the average value. The results of this study provide evidence of work attitude has a positive and significant effect on the overall equipment effectiveness (OEE), total productive maintenance (TPM) has a positive and significant effect on overall equipment effectiveness (OEE), work attitude, total productive maintenance (TPM) and overall equipment effectiveness (OEE) positive and significant impact on production continuity

This study aims to analyze the application of Total Productive Maintenance (TPM) in a pharmaceutical company in Bandung which is currently moving from an increasingly widespread industrial location, so that there are new products. TPM is a useful system in increasing productivity, increasing productivity on various production tools and equipment with only the necessary maintenance investment. Evaluation of the implementation of the TPM pillars is carried out through the overall equipment effectiveness (OEE) analysis method, visual management, lost time injury (LTI) and time accident rate (TAR). Another result is that the implementation of the planned maintenance pillar has not reached the target according to the standard, both in terms of availability and performance rate parameters. The pillar that has not been implemented in this company is autonomous maintenance. The conclusion from this research is that PT XYZ has not effectively implemented TPM in its factory operations. The recommendation from this research is the need for the implementation of autonomous maintenance pillars and scheduled replacement of engine components to solve problems that exist in the factory and can be focused in particular on critical work areas

Industry has to increase their competitiveness in order to make high profits and customer satisfaction. One of its efforts is the application of TPM (Total Productive Maintenance) in any machine production to maximize effectiveness of machine. The OEE ( Overall Equipment Effectiveness ) is used as an indicator effectiveness of the machine that important to be measured. This research aims to know to scatter value OEE in various type industries, The data in this research were obtained from collecting students' final task reports on Industrial Management Program Diploma IPB who has done internship program in the industry with the topic Total Productive Maintenance. The results indicate that average OEE value in FMCG, Textile, Chemical Industry and Manufacture Components are more than 60% but lower than 85%, so that is still below the value of the world class industry. Furthermore, availability score has reached world class standard, while performance and quality is still below world class.

PT X. is a cement manufacturing company. which experiences production losses due to the high value of downtime. Based on downtime data, the largest machine downtime value is found in the Raw Mill, so the Raw Mill machine becomes the object of research. This study aims to measure the effectiveness of the Raw Mill machine in the application of Total Productive Maintenance (TPM). The method used is Overall Equipment Effectiveness (OEE) to measure machine effectiveness and loss factor analysis with the Six Big Losses method. The results found that the average OEE value in 2022 was below the international OEE standard of 85%, namely 78% for Raw Mill Plant 10 in the 2019 period and 74% in the 2022 period. The low performance of the Raw Mill Plant 10 machine is caused by the breakdown loss factor and the reduced speed loss factor. The root causes found are lack of mechanical training and lack of control for spare parts. The recommendations given are the implementation of predictive maintenance, improving training facilities, and creating a spare parts inventory management system.

Today competitive manufacturing requires innovative approaches in the production management, as well as for customer satisfaction. Production management requires an effective and efficient maintenance management system. One approach to improve the performance of the maintenance system is through the implementation of Total Productive Maintenance (TPM). The key performance index to measure the effectiveness of TPM implementation is Overall Equipment Effectiveness (OEE). The TPM activities will eliminate equipment losses related to availability, performance rate, and quality rate. Hence, the TPM implementation will increase the OEE value. This paper outlines the theories of TPM and OEE. The paper also presents the studies carried out by different authors to show the improvement of OEE through implementation of TPM in manufacturing, such as electronic industry, steel manufacturer, as well as locomotive components manufacturer.

Nowadays, consumers expect manufacturers to provide excellent quality, reliable delivery and competitive pricing. This demands that the manufacturer's machines and processes are highly reliable. In order to possess highly reliable machines to make sure smooth manufacturing process, many organizations have implemented Total Productive Maintenance (TPM) as the enabling tool to maximize the effectiveness of equipment by setting and maintaining the optimum relationship between people and their machines. Overall Equipment Effectiveness (OEE) is used as a measure when evaluating the result of TPM. This paper intends to find out the difference between before and after the TPM implementation to OEE result. Comparison between before and after the implementation of TPM is carried out to see the difference that TPM can bring to an organization. Elements that constitute the OEE equation will be analyzed in order to identify which one that affects OEE result. After identifying, improvement will be made on that element so that OEE result will be improved ultimately. The approach used in this paper is experimental and the instruments used to collect data are observation and interview. Microsoft Excel is used to analyze data obtained and calculate OEE. Hence, TPM is a useful tool in helping firm to achieve optimal manufacturing process. By being able to achieve this level of maintenance, an organization will be able to reap competitive advantages brought by TPM, thus, producing quality products that manage to satisfy customers and subsequently generating greater profits.

Different metrics for measuring and analyzing the productivity of manufacturing systems have been studied for several decades. The traditional metrics for measuring productivity were throughput and utilization rate, which only measure part of the performance of manufacturing equipment. But, they were not very helpful for “identifying the problems and underlying improvements needed to increase productivity” [1].
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\nDuring the last years, several societal elements have raised the interest in analyze the phenomena underlying the identification of productive performance parameters as: capacity, production throughput, utilization, saturation, availability, quality, etc.
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\nThis rising interest has highlighted the need for more rigorously defined and acknowledged productivity metrics that allow to take into account a set of synthetic but important factors (availability, performance and quality) [1]. Most relevant causes identified in literature are:
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\nThe growing attention devoted by the management to cost reduction approaches [2] [3];
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\nThe interest connected to successful eastern productions approaches, like Total Productive Maintenance [4], World Class Manufacturing [5] or Lean production [6];
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\nThe importance to go beyond the limits of traditional business management control system [7];
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\nFor this reasons, a variety of new performance concepts have been developed. The total productive maintenance (TPM) concept, launched by Seiichi Nakajima [4] in the 1980s, has provided probably the most acknowledged and widespread quantitative metric for the measure of the productivity of any production equipment in a factory: the Overall Equipment Effectiveness (OEE). OEE is an appropriate measure for manufacturing organizations and it has being used broadly in manufacturing industry, typically to monitor and control the performance (time losses) of an equipment/work station within a production system [8]. The OEE allows to quantify and to assign all the time losses, that affect an equipment whilst the production, to three standard categories. Being standard and widely acknowledged, OEE has constituted a powerful tool for production systems performance benchmarking and characterization, as also the starting point for several analysis techniques, continuous improvement and research [9] [10]. Despite this widespread and relevance, the use of OEE presents limitations. As a matter of fact, OEE focus is on the single equipment, yet the performance of a single equipment in a production system is generally influenced by the performance of other systems to which it is interconnected. The time losses propagation from a station to another may widely affect the performance of a single equipment. Since OEE measures the performance of the equipment within the specific system, a low value of OEE for a given equipment can depend either on little performance of the equipment itself and/or time losses propagation due to other interconnected equipments of the system.
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\nThis issue has been widely investigated in literature through the introduction of a new metric: the Overall Equipment Effectiveness (OTE), that considers the whole production system as a whole. OTE embraces the performance losses of a production system both due to the equipments and their interactions.
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\nProcess Designers need usually to identify the number of each equipments necessary to realize each activity of the production process, considering the interaction and consequent time losses a priori. Hence, for a proper design of the system, we believe that the OEE provides designer with better information on each equipment than OTE. In this chapter we will show how OEE can be used to carry out a correct equipments sizing and an effective production system design, taking into account both equipment time losses and their propagation throughout the whole production system.
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\nIn the first paragraph we will show the approach that a process designer should face when designing a new production system starting from scratch.
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\nIn the second paragraph we will investigate the typical time-losses that affect a production system, although are independent from the production system itself.
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\nIn the third part we will define all the internal time losses that need to be considered when assessing the OEE, along with the description of a set of critical factors related to OEE assessment, such as buffer-sizing and choice of the plant layout.
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\nIn the fourth paragraph we will show and quantify how time losses of a single equipment affects the whole system and vice-versa.
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\nFinally, we will show through the simulation some real cases in which a process design have been fully completed, considering both equipment and time losses propagation.

The Overall Equipment Effectiveness (OEE) is an established method to monitor and improve the effectiveness of manufacturing processes. OEE is frequently used as a key metric in Total Productive Maintenance (TPM) and Lean Manufacturing environment. This paper focuses on the OEE measurement of the assembly line of steering gear in an automotive company (AGR Sdn Bhd) through the implementation of TPM. The average OEE measurement before implementation of TPM is 52.21% which is below the company’s target. The company used reactive maintenance, which is inherently “wasteful and ineffective. After the implementation of TPM, the OEE performance for the assembly department improved to 70.21%. The result shows that machine down time directly influence the OEE. The implementation of TPM enables the company to change their maintenance practices from reactive to proactive. The average availability percentage is 80.34% and performance efficiency average is 87.99%. This has directly contributed to a lower overall OEE performance compared to world standard. The rate of quality is maintained at an average of 99.54%.