Overall Equipment Effectiveness Value Research Articles

Analisis Produktivitas pada Mesin BM 206 D-2 Menggunakan Metode Total Productive Maintenanace (TPM) dengan Pendekatan Overall Equipment Efectiveness (OEE) di PT. Berlina Tbk

Productivity is key to success in the manufacturing industry, particularly at PT.BERLINA Tbk, which specializes in plastic packaging manufacturing. This study focuses on enhancing the operational effectiveness of the BM 206 D-2 machine trough the implementation of Total Productive Maintenance (TPM) and measurement of Overall Equipment Effectiveness (OEE) as well as the identification and mitigation of Six Big Losses. The research involves two sampling periods, each spanning two quarters. During the first period, the average OEE value of 66% indicated that the greatest losses were due to machine breakdown or Breakwon Losses, related to deficiencies in operator and technician skills, inadequate planes maintenance, and machine cleanliness. Following the implementation of improvements based on these findings, the average OEE incrased to 71% in the second period. These results underscore the importance of enhancing technical skills, effective maintenance, and strict cleanliness to improve productivity and reduce production losses.

Analisis Efektivitas Mesin Bordir Komputer Menggunakan Metode Overall Equipment Effetivenes (Oee) dan Six Big Loses pada UD. Jadi Gumilang Sukorejo

The garment company UD. Jadi Gumilang is a home-based industry located in Mojotengah Village, Sukorejo District, Pasuruan Regency, East Java. UD. Jadi Gumilang engages in the production of bags, clothes, uniforms, and embroidery, which are produced only when there are customer orders. Frequent damage to the computerized embroidery machine occurs because operators do not perform routine maintenance as per the garment's regulations. To address this issue, the Overall Equipment Effectiveness (OEE) value was calculated to analyze the major factors causing downtime. OEE itself is the result of multiplying the variables of Availability (90%), Performance (95%), and Quality (99%). After calculating the OEE value, the six big losses values were calculated to identify the highest losses that cause low OEE values. Then, from the highest loss values, a fishbone diagram (cause-and-effect diagram) analysis was conducted to identify the factors causing damage to minimize the recurrence of similar issues in the future. The results of the study show that out of the 2 computerized embroidery machines, one machine has an OEE value below 85%, which is the computerized embroidery machine 1 (84.64%). From this value, the six big losses calculations reveal that the largest loss is idling and minor stoppages losses, amounting to 20.02%. After conducting a fishbone diagram analysis, the factors causing idling and minor stoppages losses were identified as Human, Machine, Method, and Raw Material. Suggestions to prevent idling and minor stoppages losses include frequently cleaning the production area after production, regularly lubricating the machine to prevent wear, always checking the machine's condition before use, and others.

Implementation of Total Productive Maintenance in Centrifugal Pump Maintenance At Pt. Fajar Surya Wisesa

PT. Fajar Surya Wisesa specializes in manufacturing packaging paper, with its factory located in the WWTP Department. The company is dedicated to enhancing the productivity and operational efficiency of its Centrifugal Pump machines through effective maintenance strategies. This study employs a quantitative approach to assess the Overall Equipment Effectiveness (OEE), encompassing availability, performance efficiency, and quality rate, alongside a Six Big Losses analysis. The findings revealed that the average machine availability reached 98%, with a notable decrease observed in August due to downtime incidents. Performance efficiency consistently exceeded 90%, although higher production outputs occasionally led to efficiency declines. Quality rates remained stable and high, signaling advancements in production processes and quality control measures. Overall, the average OEE value attained 88%, surpassing the global standard of 85%. To further optimize Centrifugal Pump machine effectiveness, proposed enhancements include operator training, regular performance assessments, improved operator welfare considerations, selection of premium raw materials, updates to standard operating procedures (SOPs), scheduled preventive maintenance, enhanced workplace safety measures, and investments in energy backup systems. In conclusion, these initiatives have effectively elevated the performance and operational quality of the Centrifugal Pump machines at PT. Fajar Surya Wisesa.

Analysis of Cut Size Paper Cutting Machine Performance Using Total Productive Maintenance Concept (Case Study: PT. RST)

PT. RST, a leading paper factory in Indonesia, prioritizes timely production by optimizing productivity, efficiency, and paper quality. This study assesses the reliability of the Cut Size (CS) paper cutting machine, which is enhanced through the implementation of Total Productive Maintenance (TPM) as a management philosophy to ensure high-efficiency operations. To evaluate machine performance, Overall Equipment Effectiveness (OEE) measurement is used. From data collected from January to September 2023, an analysis is conducted to improve the performance of the CS machine, which has not met its set target. The average OEE value of 70.9% falls short of the target of 72%. This research aims to improve the performance of the CS machine through the TPM approach, focusing on the Focused Maintenance pillar. Using tools such as Pareto diagram, why-why analysis, fishbone diagram, and the 5W1H method, several sources of problems causing the decrease in OEE value will be identified and addressed.

Improving the overall equipment effectiveness of Sheet-Fed offset printers: A case study

This study investigates a framework for enhancing the Overall Equipment Effectiveness (OEE) of sheet-fed offset printers, focusing on the packaging sector. The research explores the understanding and implementation of OEE valuation within this context. Through a specific case study, the OEE value is 22%, with contributions from Availability, Performance, and Quality rates at 41%, 58%, and 94%, respectively. These findings underscore a substantial deviation from the world-class standard of 85%, indicating significant room for improvement. Based on Six Big Losses (SBL) and Cause and Defect diagram analysis, workers' lack of knowledge and skill and ineffective management methods are critical contributors to low OEE rates. In response, an action plan is proposed to improve OEE, aiming to reduce time losses by approximately 60% and achieve a standard OEE value. This research offers valuable insights into optimizing the efficiency of sheet-fed offset printers, offering practical strategies for enhancing productivity and competitiveness in the printing industry.

Implementation of Total Productive Maintenance on Frame Welding Machine Maintenance Using the Overall Equipment Effectiveness (OEE) Method at PT Electronics Components Indonesia

PT. Electronics Components Indonesia manufactures capacitors and focuses on enhancing productivity and operational efficiency of the frame welding machines through effective maintenance. This study employs a quantitative method to analyze the Overall Equipment Effectiveness (OEE) values, including availability, performance efficiency, and rate of quality, as well as conducting a Six Big Losses analysis. The results indicate that the average availability reached 97.83%, with a significant decrease in August due to downtime. Performance efficiency remained consistently above 90%, although higher product output tended to reduce efficiency. The rate of quality was stable and high, reflecting improvements in production processes and quality control. The average OEE value reached 88%, exceeding the global standard of 85%. To further enhance the effectiveness of the frame welding machines, suggested improvements include operator training, regular performance evaluations, attention to operator well-being, selection of high-quality raw materials, updating SOPs, regular preventive maintenance, improving workplace safety, and investing in backup energy systems. In conclusion, the improvements implemented successfully enhanced the performance and operational quality of the frame welding machines.

Unlocking Global Efficiency with Enhanced Milling Machines Worldwide

This study investigates the effectiveness of six milling machines at PT. INKA, a railroad car manufacturing company, focusing on CNC Plano 133 and Horizontal Milling 142. Utilizing Overall Equipment Effectiveness (OEE) and Age Replacement methods, the research aims to optimize machine performance and propose preventive maintenance strategies. Data spanning from January 2021 to December 2022 were collected and analyzed. Results indicate that both CNC Plano 133 and Horizontal Milling 142 exhibit suboptimal OEE values, primarily due to breakdown losses. Applying Age Replacement within 10 days significantly enhances reliability, with post-replacement reliability reaching 100%. The findings underscore the importance of preventive maintenance in improving milling machine reliability and overall productivity, thereby enhancing competitiveness and sustainability in the manufacturing sector. Highlight: Improved productivity: Preventive maintenance boosts milling machines' reliability and effectiveness. Resource efficiency: Analyzing OEE minimizes downtime, optimizes production output. Competitive edge: Enhanced performance sustains competitiveness, strengthens manufacturing sector's sustainability. Keyword: Milling machines, Overall Equipment Effectiveness (OEE), Preventive maintenance, Age Replacement, Manufacturing industry

Optimizing Auto Manufacturing: A Holistic Approach Integrating Overall Equipment Effectiveness for Enhanced Efficiency and Sustainability

In the face of pandemic-induced emergencies and unpredictable natural disasters, industries are compelled to implement rescue plans to mitigate unexpected risks. In this context, Overall Equipment Effectiveness (OEE) is considered as a key metric, followed by sustainability efforts to manage unforeseen risks, encompassing social, environmental, and economic aspects. OEE is considered as a lean tool to determine the efficiency of equipment or processes on par with the world class OEE standard, i.e., 85%. Performance, Availability and Quality as three main drivers of OEE. This research study explores the implementation of OEE in conjunction with sustainability principles in an auto sector manufacturing firm, aiming to enhance operational efficiency and sustainability practices. The research involves a 12-week initial session from April to June 2022, followed by an analysis of July to September 2022, resulting in an impressive OEE value of 48%. Notable improvements in Availability (89.75%), Performance (72.68%), and Quality (73.82%) contribute significantly. The analysis reveals enhancements in scrap rework (17%), training (16%), maintenance (13%), material availability (12%), and production capability (11%). Achievements include improvements in green profile (25%), health and safety (20%), and energy efficiency (25%), along with reductions in carbon dioxide emissions (21%), waste management (17%), and scrap (15%). This research underscores the commitment of the case study industry to sustainable development and economic growth, showcasing significant enhancements in product quality and efficiency. The integration of sustainability principles into OEE initiatives is pivotal for modern industrial optimization. The study results highlight the profound significance of this synergistic relationship, particularly within the blending section, driving substantial positive outcomes in manufacturing processes and operational excellence. The implementation of sustainability efforts not only mitigates risks and fosters growth for automotive manufacturers but also yields environmental benefits. Based on findings of this study, a roadmap for automotive manufacturers is devised to achieve robust OEE while concurrently reaping economic and environmental rewards by employing sustainability principles.

Evaluation of overall equipment effectiveness (OEE) for mining equipment (shovel-truck): A case study Manisa-Soma (Turkey) open pit mine

Mining is a costly activity that requires huge investments and large equipment. Therefore, it is crucial to use mining equipment efficiently to maximize productivity. This requires the continuous analysis of equipment efficiency and taking action to reduce negative impacts. Accurately estimating equipment efficiency is essential to increase its effectiveness. One globally recognized and accepted measurement is Overall Equipment Effectiveness (OEE). In this study was conducted to calculate the OEE values of shovels and trucks, which are the primary equipment used in open pit mining. The study presented different loss times and quality values while calculating the OEE values of mining equipment. The OEE values of electric trucks and shovels were found to be consistent with actual work quantities in the Manisa-Soma Lignite open pit operation. This study is the first applied study of OEE analysis in Turkey.

Maximizing Machine Efficiency in Indonesia's Noodle Industry

This study utilizes the Total Productive Maintenance (TPM) method, focusing on the Overall Equipment Effectiveness (OEE) to evaluate machine efficiency within a notable Indonesian noodle manufacturer. In the rapidly growing food manufacturing industry, particularly dry and instant noodles, machine performance is critical for meeting increasing domestic and international market demands. Results reveal that the OEE values are below industry standards, primarily due to speed reductions, idle and minor stoppages, process defects, and breakdown losses. These findings emphasize the urgent need for preventive maintenance strategies to mitigate downtime and enhance productivity, providing valuable insights for global industries facing similar challenges. Highlights: Rapid growth in the food manufacturing industry demands increased productivity. Machine performance is crucial for maintaining optimal production processes. Total Productive Maintenance (TPM) and Overall Equipment Effectiveness (OEE) methods help measure and improve machine efficiency. Keywords: Total Productive Maintenance, Overall Equipment Effectiveness, Six Big Losses.

Evaluation of The Effectiveness of Die Casting Machines Using Overall Equipment Effectiveness (OEE)

PT YKK Zipco Indonesia is a manufacturing company that produces zipper components, namely chains and sliders. The manufacture of slider products goes through several departments, namely die casting, assembling, painting and plating. The process of making slider products begins with the die casting department which carries out the production process using 17 machines. The problem that exists in the die casting department is that the level of productivity is quite low, so an analysis of the effectiveness of the die casting machine is needed. The aim of this research is to evaluate the performance of the production process in order to increase the efficiency and effectiveness of the company as a whole. The method used in this research is overall equipment effectiveness (OEE) and six Big Losses. The Overall Equipment Effectiveness (OEE) method is used to measure the effectiveness of production process machine performance in manufacturing companies using the parameters availability, performance and quality. In OEE there are six big losses which are categorized into 3 main categories, namely quality loss, downtime loss and speed loss. Then an analysis was carried out using the Pareto diagram and fishbone diagram to find the root causes of the problems that occurred. The results of this research, namely the results of OEE calculations on the C – 07 Die Casting machine, obtained an average OEE value of 78.6%. Based on the six big losses calculation, breakdown losses occupy the highest value with a percentage of 23.1%, making it the losses that most influence the value of machine effectiveness.

Optimizing Maintenance Efficiency with OEE Method

This study investigates the effectiveness of roving machines in a production environment by employing the Overall Equipment Effectiveness (OEE) methodology. High downtime of the roving machine significantly hampers production processes, leading to reduced machine performance and speed, resulting in suboptimal OEE values. Through OEE calculations, a value of 66.92% was obtained, highlighting considerable room for improvement towards achieving world-class standards. The findings underscore the necessity for targeted enhancements to mitigate machine downtime, thereby enhancing overall production efficiency and competitiveness in the manufacturing sector. Highlights : Efficient utilization of roving machines through OEE optimization is crucial for enhancing production performance. High downtime of roving machines significantly impedes production processes, leading to decreased efficiency and competitiveness. Addressing downtime issues can lead to substantial improvements in overall production efficiency, aligning operations with global standards. Keywords: Roving machine, Overall Equipment Effectiveness (OEE), Production efficiency, Downtime reduction, Manufacturing competitiveness

Overall Equipment Effectiveness (OEE) in Micro-Surgical Device Manufacturing

In the micro-surgical device manufacturing industry, well-maintained machines, detailed process instructions, and standard reference tools can ensure maximum utilization through good product quality, efficient time, and minimum cost. This study investigates a series of micro-surgical device manufacturing processes to propose an advanced strategic operational plan based on a real-time data analytics concept called Overall Equipment Effectiveness (OEE) to improve overall maintenance along with better machine performance and product quality. This new framework was developed within a micro-surgical device company. Still, the firm desires to keep its identity and some other aspects of its processes and products confidential, so with their blessing and support, this article will cover the aspects of OEE applied to their situation. The data shown and evaluated in this paper is representative and accurate to the improvements achieved. The problemsolving tools used in the past were implemented on individual machines, equipment, processes, operators, etc. This holistic and novel approach makes sure that the OEE is conducted across all the machines in the processes, not on each machine or process separately. The main contributing elements that lower OEE are reworks, downtime, rejection rate, and unbalanced cycle times. Each element has two sub-elements that combine to form the six big losses. However, a unified approach like the OEE was never utilized. So, a new framework was designed based on the OEE model using an amalgamation of problem-solving tools to overcome the identified problems and reduce the contribution of the three big losses. This advanced model of OEE provides a complete guide to decrease the share of big losses to improve the value of OEE. The proposed model includes problem-solving tools and a conventional OEE model for a complete framework. After the successful implementation of the proposed model, a significant reduction in the value of three big losses was observed, ultimately improving the value of OEE factors for the machines by 48%.

TINJAUAN PRODUCTIVE MAINTENANCE MESIN LAMINASI PACKAGING PADA PT. ULTRA PRIMA PLAST

This research was conducted to measure the effectiveness and application of the Total Productive Maintenance (TPM) method, especially on the Focused Improvement pillar on the Printing Packaging machine at PT. Ultra Prima Plast. The research was conducted using quantitative data and an Overall Equipment Effectiveness (OEE) analysis approach. The OEE value was analyzed using Six Big Losses (SBL) to find the dominant factor causing the loss. The loss factor is then classified with the 80/20% formula as a reference for making Fishbone Diagrams. Fishbone Diagram analysis is carried out to find the cause and effect or root cause of each loss. The root of the problem obtained is then given a suggestion for improvement and analyzed using the 5W+1H method. The results of the study obtained an average value of Overall Equipment Effectiveness (OEE) of 28%. This value is obtained from several calculations including the Availability Rate 97%, Performance Rate 20% and Quality Rate 98%. This value is still below the world category that has been seet by JIPM. which is 85%. The losses on the printing packaging machine are yield losses wich is 58% and reduce speed losses which is 23%. The roots on the problem found were the absence of planed maintenance and autonomus maintenance on Laminasi packaging machine and unmaintained environment inadequate knowlage of human resources and negligance of work procedures in the field.

Integration of Overall Equipment Effectiveness and Six Sigma Approach to Minimize Product Defect and Machine Downtime

This study was conducted in a company that produces palm oil-based products such as cooking oil and margarine. The study aimed to encounter defects in packaging pouches. This study integrated the overall equipment effectiveness (OEE) with the six sigma DMAIC method. The OEE was performed to measure the efficiency of the machine. Three factors were measured in OEE: availability, performance, and quality. These factors were calculated and compared to the OEE world-class value. Then, the Multiple Linear Regression was performed using SPSS to determine the correlation between measurement variables toward the OEE value. Lastly, the six sigma method was implemented through the DMAIC approach to find the solution and improve the packaging quality. Supposing the recommendations are implemented, the OEE is expected to increase from 82% to 85%, with availability ratio, performance ratio, and quality ratio at, 99%, 86%, and 99.8%, respectively.

Optimizing Digging Equipment Productivity Using Overall Equipment Effectiveness (OEE) Method in Coal Overburden Mining Activities

Coal companies have an overburden stripping production target of 95,000 bcm in January 2022, while the realization of production with the Sumitomo SH 350 LHD excavator and Hitachi Zaxis 350 H excavator is only 77,000 bcm or 82% of the production target. The purpose of this study was to obtain an analysis of the productivity of the Sumitomo SH 350 LHD Excavator (40) and Hitachi Zaxis 350 H Excavator (31) in the overburden stripping activity in January 2022, analyze the obstacle factors that caused the available working hours to be reduced by using the Fishbone diagram method, get an analysis of the Overall Equipment Effectiveness (OEE) value of the Sumitomo SH 350 LHD Excavator (40) and Hitachi Zaxis 350 H (31) Excavator before being optimized, and get the analysis and productivity of the Sumitomo SH 350 LHD Excavator (40) and the Hitachi Zaxis 350 H Excavator (31) which has been optimized with the implementation of Overall Equipment Effectiveness (OEE) to achieve the overburden stripping production target. After analysis and improvement efforts, the total overburden stripping production was 149,000 bcm, which means that it has reached the target and even exceeded the production target of 95,000 bcm/month with the OEE value of the digging equipment of 41% and 43%, respectively. However, the OEE value is still very low compared to the world-class standard OEE value, which is 85% and there is still room for improvement.

Analysis of Effectiveness of Cut Size Line Machines Based on Total Productive Maintenance (TPM) and Analytical Hierarchy Process (AHP) - A Case Study

This research aims to analyze the implementation of Total Productive Maintenance (TPM) using Overall Equipment Effectiveness (OEE) and Analytical Hierarchy Process (AHP) approaches to increase the OEE value on cut-size line machines in the finishing department in PT. X. The research methodology was carried out by calculating OEE and significant loss values, analyzing Pareto and Fishbone diagrams, and using the AHP as a decision-making method. Then, the recommendations for implementing focused and autonomous maintenance in the case study company. The research results revealed that the significant influencing factor for the OEE value was engine speed, which causes performance efficiency to decrease so that the OEE value also decreases. The OEE value in 2021 is 74%. The improvement plan by applying the TPM and AHP methods will be expected to increase the performance efficiency of the machine via OEE value from 74% in 2021 to 79% for the coming year 2023/2024.

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.

Measurement Of Total Productive Maintenance (TPM) Using The Overall Equipment Effectiveness (OEE) Method On Fermentation Machinery At Pt. Indo Acidatama Tbk

Ethanol, or ethyl alcohol, has many applications in a variety of industries, including as a solvent, fuel, and in pharmaceuticals. Demand for ethanol in Indonesia is high, but domestic production is not sufficient, which prompted the establishment of PT. Indo Acidatama Tbk in 1986. This company produces ethanol from sugar cane molasses through a fermentation process using the yeast saccharomyces cerevisae strain Kyowa. The fermentation process requires good care to ensure optimal results and prevent machine failure. This research aims to measure the Overall Equipment Effectiveness (OEE) value of the fermentation machine at PT Indo Acidatama, identify the factors that influence the production performance of the fermentation machine, and determine the main causes of losses that affect the effectiveness of the fermentation machine. The research results show that the OEE value of the fermentation machine at PT Indo Acidatama in January 2023 is 85%, which is in accordance with JIP standards. The main causes of loss of machine effectiveness are breakdown losses (8.7%), reduced speed losses (5.9%), and rework losses (0.2%). To increase the effectiveness of fermentation machines, it is recommended to adjust process parameters, provide training to staff, and carry out regular data monitoring.

Increased Productivity of Packing Machines Through Implementation of Total Productive Maintenance Using the Overall Equipment Effectiveness Method Case Study of PT. GFPJ

In the world's manufacturing industry, increasing productivity is very important in fulfilling domestic and international markets as well as maintaining customer confidence. The company is trying to increase productivity in production. The fact that the packing machine is in an inefficient condition and the management is trying to implement it. in Total Productive Maintenance (TPM) to maximize the effectiveness of machine facilities in the industry. Then corrective actions are tested using the Overall Equipment Effectiveness (OEE) method, which is the calculation method used in this OEE value is determined by availability, performance and quality. The low OEE value of the packing machine at PT. GFPJ results from the availability value of = 60% for the results of the performance value of = 100% and the value of quality = 93%, it can be concluded that the OEE value obtained on the machine packing is 59.86%, while the international OEE standard is 87%, so it needs improvement. The factor that becomes a priority for improvement is the performance or performance of the machine in producing concrete, because the performance value is the lowest value of the three factors that affect the OEE value.