INCREASING MACHINE UTILIZATION USING TOTAL PRODUCTIVE MAINTENANCE IN DIE CAST MACHINE IN TOY MANUFACTURING COMPANY

Abstract

The purpose of this thesis is to reduce the number of high downtime in a toy manufacturing company. Previously, the company was evaluated through overall equipment effectiveness for all the production area and managed to highlight one area that score lowest, which is the die cast area, with an average score of 54%. The low availability of die cast impacted negatively on its OEE performance. Thus, to reduce the high downtime, Total Productive Maintenance is employed through some of its programs especially the preventive maintenance. The research will analyze deep-dive to one pilot equipment that has been causing a high downtime to the area. The research will design a preventive maintenance schedule and other TPM implementation that focuses on total employee involvement, from top level management to regular workers, in purpose to improve the overall equipment effectiveness percentage, but also impacted the company culture to have a lean thinking. The OEE result after the TPM implementation increased by 18%, from a 5-month average of 54% to 72% in 3 months progress. The increase of high reliability has an impact to the equipment performance and to high OEE score.