Rancangan Perbaikan Sistem Total Productive Maintenance di PT. XYZ

Abstract

PT. XYZ is a soft drink packaging company located in Tanjung Morawa, North Sumatra. Although it has implemented the concept of Total Productive Maintenance (TPM) but in the process of making tea bottles, machines are still had breakdown. Based on the calculation of OEE (Overall Equipment Effectiveness) concluded OEE has not reached the ideal conditions (<85%) so that the implementation of TPM does not meet its targets. The research objective was to determine the effect of each variable consists of eight pillars of TPM performance. Based on the identified variables that influence factor TPM targets are not achieved then draft the TPM system improvements based on those factors. Based on the analysis concluded that the performance of TPM, kaizen and quality maintenance pillar is the variable with the lowest target achievement with a focus on the improvement of employee participation in the system suggestions and GKM advice, work with standards compliance, as well as the ability to increase yield and improve employee work standards. Repair TPM system design is based on Toyota's six-step improvement with a focus on the improvement of GKM activities by forming a group that includes all employees, divide the facilitator for each group and the proposed creation of work standardization guidelines. Improvement suggestions to the proposed scheduling periodic and routine evaluation of suggestions system and appropriate award for any advice received and the implementation of the PDCA cycle so improvement activity can be carried out continuously.

PT. XYZ merupakan perusahaan minuman ringan kemasan yang berlokasi di Deli Serdang, Sumatera Utara. Walaupun telah menerapkan konsep Total Productive Maintenance (TPM) tetapi pada proses pembuatan teh kemasan botol, mesin masih mengalami breakdown. Berdasarkan hasil perhitungan OEE (Overall Equipment Effectiveness) disimpulkan OEE belum mencapai kondisi ideal (< 85%) sehingga implementasi TPM belum sesuai dengan target perusahaan. Tujuan penelitian adalah untuk mengetahui pengaruh setiap variabel yang terdiri dari delapan pilar TPM terhadap kinerja TPM. Berdasarkan variabel yang berpengaruh tersebut diidentifikasi faktor penyebab target TPM tidak tercapai kemudian menyusun rancangan perbaikan sistem TPM berdasarkan faktor tersebut. Berdasarkan hasil analisis dan pembahasan penelitian disimpulkan bahwa kinerja TPM, pilar kaizen dan quality maintenance merupakan variabel dengan pencapaian target terendah dengan fokus perbaikan pada indikator partisipasi karyawan terhadap sistem saran dan GKM, kesesuaian hasil kerja dengan standar, serta kemampuan karyawan meningkatkan hasil dan memperbaiki standar kerja. Perbaikan rancangan sistem TPM dilakukan berdasarkan enam langkah perbaikan Toyota dengan fokus perbaikan pada aktivitas GKM dengan membentuk kelompok yang mencakup seluruh karyawan, membagi fasilitator untuk setiap kelompok dan mengusulkan pembuatan standarisasi pedoman kerja. Perbaikan sistem saran dengan mengusulkan pembuatan jadwal evaluasi saran secara berkala dan rutin, memberikan penghargaan yang sesuai untuk setiap saran yang diterima serta implementasi siklus PDCA agar aktifitas perbaikan dapat dilakukan secara terus-menerus.