DEVELOPING MAINTENANCE PROCEDURE TO REDUCE BREAKDOWN IN CAPPING AND CARTONING MACHINE AT PT. XYZ MANUFACTURING INDONESIA

Abstract

PT. XYZ Manufacturing Indonesia is a factory engaged in the manufacture of cosmetics. PT. XYZ Manufacturing Indonesia is the biggest manufacture XYZ in the world. With the huge number of production line, meaning that the factory will face lots of problem in machine performance. Due to limitation of time, this research is focus on production line Jar J5. In the last four month, the production efficiency or OEE in line Jar J5 cannot archive the target. The production efficiency target for line Jar J5 is 60%, but based on historical data in the last four month the line efficiency only reaches 56.3%. The decreasing of efficiency happened because of the losses that coming from breakdown, changeover, and waiting during production time. Pareto analysis is perform to see the biggest line stop coming from each losses. Based on Pareto analysis it show that breakdown time make the efficiency decreased more than 60% and machine that produce the highest breakdown are capping and cartoning machine. FMEA is apply for finding the area that make the machine breakdown. After knowing the core problem, 5 whys analysis is used to find the root cause. Based on 5 whys analysis, maintenance procedure are needed to obtain the optimum production. Maintenance procedure are applied in caping and cartoning machine. During seven week of implementation maintenance procedure, breakdown time in capping and cartoning machine decreased from 466 minutes to 138 minutes, the overall equipment efficiency also improved from 50% to 65%.