ANALISIS FAKTOR-FAKTOR PENYEBAB MENURUNNYA EFEKTIVITAS DAN USULAN PENINGKATAN KINERJA PADA MESIN ROLL BENDING DI PT XYZ

Abstract

The overall measurement of the effectiveness of the MCB 3045-WT type roll bending machine was carried out using the TPM concept, namely Overall Equipment Effectiveness (OEE), Net Equipment Effectiveness (NEE) and Total Effective Equipment Performance (TEEP). OEE is based on three elements, namely availability, performance efficiency, and rate of product quality. On the other hand, NEE is calculated based on up time, performance efficiency, and rate of product quality. TEEP itself refers to the loading portion factor and OEE value. From the analysis carried out, the OEE percentage was recorded at 73.79%, 72.31%, 57.47%, 68.77%, 73.17%, and 70.76%, respectively. The NEE percentage also showed consecutive figures of 73.65%, 72%, 65.43%, 68.45%, 73.02%, and 72.54%. Meanwhile, TEEP had percentages of 57.11%, 59.83%, 46.34%, 59.60%, 56.63%, and 56.60%, respectively. Equipment failure losses were recorded at 2.09%, 4.32%, 4.93%, 4.56%, 2.61%, and 3.40%, respectively. Setup and adjustment losses were recorded at 1.3%, 1.2%, 1.3%, 1.2%, 1.2%, and 1.2%, respectively. Idling and minor stoppage losses were around 0.7%, 0.8%, 0.8%, 0.8%, 0.8%, and 0.7%, respectively. The percentages of reduced yield loss were 12.70%, 12.06%, 10.44%, 12.40%, 12.08%, and 9.77%, respectively. The defect loss figures were 9.5%, 9.4%, 12.3%, 12.3%, 10.2%, and 8.8%. Meanwhile, the percentages of reduced yield loss were 1.2%, 0.8%, 1.8%, 1.6%, 1.1%, and 1.3%. Factors causing the decline in effectiveness due to reduced speed losses and defect losses include human, method, machine, and material aspects. Suggestions for increasing machine effectiveness include implementing periodic training and evaluation programs, updating ideal cycle time calculations by comparing them with actual cycle times, implementing autonomous maintenance, cleaning plates from dirt or dust, and implementing a 5S work culture.