Application Of Total Productive Maintenance Research Articles

Measurement of effectiveness spinning fiber machines using total productive maintenance method at textile manufacturing

PT XYZ is a textile industry manufacturing company whose main products are Polymer Chips, Pre-Oriented Yarn (POY), Draw Twister Yarn (DTY), Bi Shrankage Yarn (BSY), and Polyester Staple Fiber (PSF) which are marketed domestically and internationally. There are still high breakdown problems, which can hamper the production process and result in a decrease in production capacity. The purpose of this study was to measure the Performance Effectiveness of Fiber Spinning Machines using the Total Productive Maintenance (TPM) Method and to find the causes of the Six Big Losses that affect the Performance Effectiveness of Fiber Spinning Machines. The application of TPM in the manufacturing industry aims to extend machine life and maximize the effectiveness of machine performance. The results of measuring the Performance Effectiveness of Fiber Spinning Machines using the TPM Method obtained an Overall Equipment Effectiveness (OEE) value of 87.85% and the cause of Six Big Losses that affect the effectiveness of the performance of Fiber Spinning Machines is Equipment Failure Losses, the most dominant factor is the Human Factor, namely lack of control, lack of understanding of Standard Operational Procedure (SOP), lack of thoroughness when cleaning spinnerets.

UNJUK KERJA MESIN VERTICAL RAW MILL PLANT 10

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.

INCREASING PROFITABILITY OF A MANUFACTURING COMPANY BY USING THE TOTAL PRODUCTIVE MAINTENANCE APPROACH: A REVIEW

In the modern world, a company pays serious attention to productivity and efficiency. Several sectors in the manufacturing world are starting to carry out business transformation, particularly those leading to industry 4.0. This circumstance is driven by efforts to achieve higher productivity and efficient process, mainly after being economically hit by the Covid-19 pandemic. To maintain efficiency, a manufacturing company should maintain its machine and equipment. Total productive maintenance is a system based on the concept of preventive and predictive maintenance. It is designed to prevent losses resulting from many factors, e.g. work stoppages due to failures and adjustments, speed losses due to minor stops and speed reductions, and losses due to defects. The total productive maintenance also provides a tool to measure the level of effectiveness of a machine, i.e. overall equipment effectiveness. This review paper focuses on the application of total productive maintenance and overall equipment effectiveness in determining the effectiveness of equipment and eliminating the factors affecting the effectiveness of the equipment.

INCREASING PROFITABILITY OF A MANUFACTURING COMPANY BY USING THE TOTAL PRODUCTIVE MAINTENANCE APPROACH: A REVIEW

In the modern world, a company pays serious attention to productivity and efficiency. Several sectors in the manufacturing world are starting to carry out business transformation, particularly those leading to industry 4.0. This circumstance is driven by efforts to achieve higher productivity and an efficient process, mainly after being economically hit by the Covid-19 pandemic. To maintain efficiency, a manufacturing company should maintain its machine and equipment. Total productive maintenance is a system based on the concept of preventive and predictive maintenance. It is designed to prevent loss resulting from many factors, e.g. production interruption due to failures and adjustments, speed loss due to minor stops and speed reductions, and loss due to defects. Total productive maintenance also provides a tool to measure the level of effectiveness of a machine, i.e., overall equipment effectiveness. This review article focusses on the application of total productive maintenance and overall equipment effectiveness to determine the effectiveness of equipment and eliminate the factors that affect the effectiveness of the equipment.

ANALISIS PENERAPAN TOTAL PRODUCTIVE MAINTANANCE (TPM) DENGAN MENGGUNAKAN METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE) DI PT XYZ

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

Occupant Awareness towards the Application of Total Productive Maintenance in Green Office Building

Total productive maintenance (TPM) can be beneficial to be applied in green building. Successful TPM application requires total participation of the occupants in green building. However, lack of occupant awareness and involvement are the barriers of TPM application in green building. Thus, this paper aims to examine the aspects of occupant awareness and occupant involvement in operation and maintenance of green building. A questionnaire survey was performed among the occupants of green office buildings in Malaysia with 417 valid responses. Descriptive analysis was used to identify the level of occupant awareness and involvement in the operation and maintenance activities. Then, Wilcoxon signed-rank test was run to examine the difference between occupant awareness and occupant involvement in the operation and maintenance activities. The results have demonstrated significant difference between the occupant awareness and occupant involvement, whereby the levels of occupant awareness aspects were above average, while the level of occupant involvement was below average. Since TPM concept in green building aims for total participation of occupants in operation and maintenance activities, the increase of occupant involvement is necessary. The occupants will be confident to take part in operation and maintenance activities if they are equipped with relevant competencies, skills and knowledge. Therefore, comprehensive training and education programmes are recommended to upskill the occupants’ knowledge and skills.

Literature Review of the Application of Total Productive Maintenance (TPM) in various industries in Indonesia

This research is a literature review from various journals with the theme Total Productive Maintenance which is implemented in various companies in Indonesia. The purpose of this paper is as a means of sharing and learning between companies that can be taken as a brainstorming theme related to machine performance within a company, which may not occur between companies that problems outside of the machine problem. The OEE factor of the machine is one of the parameters that is the goal which results in poor engine performance. The research method is to search journals from various sources that have keywords related to TPM. The number of journals found from 2015 to 2020 was 60 journals which were finally iterated to become 46 journals to be selected for this paper. The concept of Pareto and Root caused Analysis (4M + E) is a helpful tool in concluding the literature review in this paper, while the TPM Pillar will provide a solution guide for each problem that has been summarized in 4M + E which will be classified from each problem to be the solution of the problem. that has been found. The conclusions of this literature review are related to this new card problem which is the focus of attention. It is the result of operator changes associated with the contract system which causes this change to be properly prepared at the time the new operator works. The previous operator's method that has been good needs to be transferred to the operator that will enter. However, this is often a big gap with the preparation of this skill transfer and the fatigue factor of operators who have side jobs, with the proliferation of online-based applications causing business operators to seek additional income so that their main work is neglected.

Application of total productive maintenance in service organization

This paper discusses the application of TPM in copy centre in Woldia University located in Woldia town, north wollo, Amhara region, Ethiopia. The problem encountered in the centre includes long waiting time due to frequent breakdown of equipment, unpleasant work environment, defective product etc. This leads to disrupt of the university programs such as exams, trainings and so on. This paper uses TPM for solving the above mentioned problem by employing Overall equipment effectiveness (OEE). The OEE value on the centre is 35% which is less than world class standard of 85%. Therefore, the center needs urgent improvement in typical equipment maintenance management program. Advantages of TPM for the center includes better utilized equipment, clean and pleasant workplace, highly motivated employee, and satisfied customer.

Descriptive analysis of Overall Equipment Effectiveness (OEE) in various industry

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.

Evaluating 8 pillars of Total Productive Maintenance (TPM) implementation and their contribution to manufacturing performance

TPM is one method to improve manufacturing performance through an emphasis on maintenance that involves everyone in the organization. Research on the application of TPM and its relevance to the manufacturing performance has been performed quite a lot. However, to the best of our knowledge, a study that deliberates how the application of 8 pillars TPM (especially in developing countries) is still hard to find. This paper attempts to evaluate in more detail about how the 8 pillars of TPM are applied in Indonesia and their impact on manufacturing performance. This research is a pilot study with a target of 50 companies. From the results of data collection, only 22 companies (44%) are eligible to process. Data processing was performed using SPSS and Smart PLS tools. From the validity and reliability tests, it can be seen that all items/indicators for TPM pillars are valid and reliable with correlation value (R) of 0.614 - 0.914 and with Cronbach’s alpha equal to 0.753. As for the Manufacturing Performance construct, the Delivery indicator was not valid. In overall, the model is reliable with Cronbach’s alpha of 0.710. From the results of Confirmatory Factors Analysis (CFA) for TPM, it can be seen that four indicators (pillars) are highly significant while four other indicators are less significant. For MP, three indicators are significant, and two are not significant. In general, the structural model of the relationship between TPM and MP is relatively strong and positive with values R = 0.791, and R squared = 0.626. This means that the TPM Pillars can explain 62.6% MP variability construct variable, while the other 37.4% can be explained by unrelated variables.

Kajian Pengaruh Struktur Organisasi, Komitmen Karyawan, dan Pemahaman Tujuan Operasi terhadap Penerapan Total Production Maintanance (TPM) serta Implikasinya pada Kinerja Karyawan

The purpose of this study to identify, analyze and assess: the influence of organizational structure,employee commitment and understanding of the purpose of operating the company's total productivemaintenance slate pencil group, and total productive maintenance influence on employee performance of thecompany's operations slate pencil group. This research is descriptive and verification. The populations in thisstudy were employees of the company's operations slate pencil, while the unit observer is a staff of about1,868 people with a sample of 317 employees. Analysis of the data using Path Analysis. The results of this study showed that there is a significant effect partially, either directly or indirectlybetween the variables of organizational structure, employee commitment and understanding of the operationalobjectives of the implementation of total productive maintenance. Contributions amount of influence on theorganizational structure of the implementation of total productive maintenance in second place. There is a simultaneous effect between organizational structure, employee commitment andunderstanding of the operational objectives of the implementation of total productive maintenance. Operationobjective understanding of the application of total productive maintenance have the most influence among thethree variables studied and followed by the organizational structure and employee commitment. Influence simultaneously or jointly variable organizational structure, employee commitment, andunderstanding operating purposes of the application of total productive maintenance at 0.616. While theremaining 38.4% is influenced by other variables outside the model is not examined. There is the influence ofthe implementation of total productive maintenance on employee performance of operations with the amountof influence of 73,2% (seventy-three point two) percent. Thus the effect of the implementation of totalproductive maintenance on employee performance of operations is very significant.

Application of TPM indicators for analyzing work time of machines used in the pressure die casting

The article presents the application of total productive maintenance (TPM) to analyze the working time indicators of casting machines with particular emphasis on failures and unplanned downtime to reduce the proportion of emergency operation for preventive maintenance and diagnostics. The article presents that the influence of individual factors of complex machinery maintenance (TPM) is different and depends on the machines' modernity level. In an original way, by using correlation graphs, research findings on the impact of individual TPM factors on the castings quality were pre- sented and interpreted. The examination results conducted for machines with varying modernity degrees allowed to determine changes within the impact of individual TPM factors depending on machine parameters. These results provide a rich source of information for the improvement processes on casting quality of the foundry industry that satisfies the automotive industry demand.

Learning curve analysis in total productive maintenance

The continuous improvement concepts such as total quality management, just-in-time and total productive maintenance have been widely recognized as a strategic weapon and successfully implemented in many organizations. In this paper, we focus on the application of total productive maintenance (TPM). A random effect non-linear regression model called the Time Constant Model was used to formulate a prediction model for the learning rate in terms of company size, sales, ISO 9000 certification and TPM award year. A two-stage analysis was employed to estimate the parameters. Using the approach of this study, one can determine the appropriate time for checking the performance of implementing total productive maintenance. By comparing the expected overall equipment effectiveness (OEE), one can improve the maintenance policy and monitor the progress of OEE.