Analisis Pengukuran Efektivitas Mesin Menggunakan Overall Resource Effectiveness dan Six Big Losses di UD. Herman Jaya

Abstract

UD. Herman Jaya is a company engaged in the production of wooden frames. In the period March 2024-February 2025, the company experienced a decrease in productivity due to damage to wood splitting machines, which had an impact on the increase in defects/rework products and delays in the supply of wood materials. This study aims to measure the effectiveness of wood splitting machines using the Overall Resource Effectiveness (ORE) method, identify the types of losses based on six big losses, analyze the root causes of losses through the use of Failure Mode and Effects Analysis (FMEA) and provide improvement proposals with a Total Productive Maintenance approach (TPM). The calculation results show that the average ORE value of wood splitting machines is 62.98%, which is below the Japan Institute of Plant Maintenance (JIPM) standard of 85%. The three main types of losses that cause low ORE values are reduced speed losses (8.09%), defect/rework losses (4.66%), and breakdown losses (3.77%). Based on FMEA analysis, gearbox damage is the main cause of reduced speed losses with the highest Risk Priority Number (RPN) value of 392. Meanwhile, defects/rework losses were caused by the absence of checking the results of the timber (RPN 336) and breakdown losses were caused by the application of machine maintenance after damage occurred (RPN 336). Proposed improvements to improve the effectiveness of the machine through the implementation of TPM pillars, namely autonomous maintenance, by involving the operator in the maintenance and responsibility of the machine; focused maintenance by addressing damage to critical components; planned maintenance with routine preventive scheduling; quality maintenance with improved machine quality control to prevent defective products (rework products); training by evaluating performance and providing training to operators; and safety, health, and environment, by implementing daily cleaning schedules, providing PPE, and improving occupational safety aspects