IMPLEMENTATION OF PREVENTIVE MAINTENANCE SYSTEM IN AUTO MACHINE TOY ASSEMBLY TO INCREASE MACHINE RELIABILITY IN TOY MANUFACTURING COMPANY

Abstract

During the production process, machine performance can be seen from the data of machine downtime. Machine with greater number of downtime is the machine that has a low reliability. The objectives of this study are to identify the components which activate dowtown machine and to propose the shcedule of preventive maintenance. The data was taken in Toy assembly area (TA) of toy manufacturing company in Jababeka and observation was used to collect the data. To develop preventive maintenance schedule in order to get the interval time of machine failure based on target of reliability, several steps which are analyzing the current data based on the types of components, calculating Time to Repair (TTR), time to failure (TTF), mean time to repair (MTTR) and mean time to failure (MTTF) were used. The calculation of each component is based on the failure distribution that fit for the components failure data. After implementing the preventive maintenance, the result of the calculation in the proposed condition shows that all the component can achieve the target of reliability 80% with the average reliability of each component increase by 50.7%. In addition, through the implementation of preventive maintenance,cost of maintenance reduces by 21% on average, production loss can be eliminated and downtime reduces by 9% on average.