Analisis Efektivitas Mesin Extruder Menggunakan Overall Equipment Effectiveness dan Six Big Losses di PT. Industri Invilon Sagita

Abstract

PT. Industri Invilon Sagita is a company that produces PVC-based products such as doors, pipe fittings, sills, cable covers, pipe glue, and pipes. Every day the machines used work 24 hours divided into 3 shifts. This makes the importance of the effectiveness of production machines so that they can be used optimally in the production process. One of the machines used in making PVC pipes is an extruder machine. An extruder machine is a machine that functions to process PVC material from powder form into ready-to-print dough through a heating process. However, in reality, what happens in the field, this machine often experiences interference or damage which makes this machine unable to operate optimally. Therefore, this study aims to calculate the value of the effectiveness of the extruder machine using the Overall Equipment Effectiveness (OEE) method. The OEE value is then identified using the Six Big Losses method to obtain the loss factor. Then, an analysis was carried out using five why analysis, fishbone diagrams, and the Failure Mode & Effect Analysis method to find the root of the problem and design a proposed improvement. The results of the research show that the OEE of the extruder machine in 2022 is 66.56% or is included in the standard category. The low OEE value is caused by a performance rate factor of 86.13% and a quality rate of 81.09% which is still below world-class standards. The low value of the performance rate is due to the high value of idling & minor stoppage losses and reduced speed losses. Idling & minor stoppages have an average loss value of 42.96%, a loss time of 282.06 hours, and a percentage of losses of 56.66%. Reduced speed losses have an average of 13.01%, a loss time of 86.31 hours, and a percentage of losses of 17.33%. Meanwhile, the low-quality rate is influenced by the high value of reject losses by having an average loss of 15.65%, a loss time of 99.98 hours, and a percentage of losses of 20.08%. There are several proposed improvements that can be implemented based on the 8 pillars of TPM, namely education & training, focused improvement, autonomous maintenance, and planned maintenance.