Analisis Total Productivity Maintenance (TPM) Mesin Water Jet Loom (WJL) di PT. XYZ Menggunakan Metode Overall Equipment Effectiveness (OEE)

Abstract

Riset ini difokuskan guna mengevaluasi derajat efektivitas operasional permesinan Water Jet Loom (WJL) pada departemen penenunan (weaving) di PT. XYZ melalui pengaplikasian pendekatan Overall Equipment Effectiveness (OEE), beriringan dengan perumusan anjuran perbaikan berbasis Total Productive Maintenance (TPM). Mesin WJL memegang fungsi krusial dan amat vital di dalam lini produksi kain tenun. Kendati demikian, tingginya lonjakan angka waktu henti (downtime) dan malfungsi onderdil telah memicu kemerosotan laju produktivitas perusahaan. Kalkulasi efektivitas diukur menyandarkan pada tiga variabel pokok, yang bermuara pada capaian rata-rata availability ratio di angka 57,3%, performance efficiency sebesar 76,4%, serta rate of quality product menyentuh angka absolut 100%. Beranjak dari hasil hitung tersebut, didapatkan persentase komposit nilai OEE total di level 44,4%. Capaian operasional ini terbukti masih tertinggal jauh di bawah ambang batas ideal manufaktur berskala global (World Class) yang dipatok pada angka 85%. Guna membongkar akar pemicu anjloknya skor OEE ini, penyelidikan dilangsungkan memanfaatkan instrumen bantu cause and effect diagram (diagram tulang ikan). Luaran analisis sukses memetakan aneka ragam kendala yang berpusat pada empat elemen fundamental, yakni ranah mesin (keausan onderdil dan krisis stok suku cadang), metode (ketidakoptimalan prosedur standar perawatan), manusia (minimnya wawasan pelatihan dan lambannya waktu tanggap pekerja), beserta lingkungan (situasi area pabrik yang lepas dari kendali). Sebagai jalan keluar untuk memberantas problematika tersebut, direkomendasikan pengaplikasian 8 pilar TPM secara menyeluruh yang ditopang kukuh oleh fondasi konsep 5S. Pendekatan intervensi ini diproyeksikan sanggup mendongkrak keandalan sistem mekanis, menekan downtime, sekaligus memaksimalkan laju produktivitas maupun efisiensi korporasi dengan berkesinambungan.

This research is designed to thoroughly assess the operational effectiveness of the Water Jet Loom (WJL) machinery within the weaving department at PT. XYZ applying the Overall Equipment Effectiveness (OEE) framework, while proposing strategic enhancements founded on Total Productive Maintenance (TPM) principles. The WJL equipment acts as a highly vital component in the woven fabric production process. Nevertheless, the frequent occurrence of machine downtime and component malfunctions has severely undermined the company's productivity levels. Effectiveness was gauged using three primary variables, yielding an average availability ratio of 57.3%, a performance efficiency of 76.4%, and a flawless rate of quality product at 100%. Integrating these metrics, the aggregate OEE formulation stood at 44.4%. This figure drastically falls short of the recognized world-class manufacturing benchmark established at 85%. To trace the root triggers causing this poor OEE performance, an investigation was executed using a cause and effect diagram (fishbone diagram). The diagnostic outcomes pinpointed multiple issues stemming from four core factors: machine (deteriorating parts and spare part shortages), method (ineffective standard maintenance procedures), human factors (inadequate training and sluggish response times), and environment (unregulated production floor conditions). To decisively resolve these setbacks, a comprehensive rollout of the 8 TPM pillars, underpinned by the 5S principles, is strongly proposed. This strategy is anticipated to elevate equipment reliability, successfully curtail machine downtime, and sustainably optimize both corporate productivity and operational efficiency over the long term.