IMPROVEMENT OF OVERALL EQUIPMENT EFFECTIVENESS (OEE) IN ROTOCASTING PROCESS OF PT RTC USING TOTAL PRODUCTIVE MAINTENANCE (TPM) APPROACH

Abstract

There are several wastes occurs in rotocast area during the production process in January that results low of OEE rate in PT RTC. The two biggest wastes are machine breakdown and amount of defects. Because of that, TPM system is implemented. The research analysis is focused on reducing the machine breakdown and defects from six big losses analysis and failure mode and effect analysis (FMEA). The wastes can cause potential low production rate that does not meet the target in January 2018. Initial observation is to calculate the OEE variables which are availability rate, performance rate, and quality rate. From the initial performance, the OEE rate is below world class. After that, identify the problem and analyze within six big losses analysis, FMEA and Cause and Effect Diagram. Based on the problem analysis, there are two problems that has big impacts into performance losses, and furthermore will be focused on which are push failure and material jams. After problem identified, the next steps are improvement and TPM implementation. Some improvements have been implemented are making dispenser data sheet, making mold checklist sheet, making min-max label and adding yellow box into machine. The improvement actions will reduce all aspects of the losses and can increase the OEE rate from 66.8% in January into 88.9% in February and 93.7% in March.