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IMPLEMENTASI TOTAL PRODUCTIVITY MAINTENANCE (TPM)

IMPLEMENTASI TOTAL PRODUCTIVITY MAINTENANCE (TPM). Nazaruddin.

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IMPLEMENTASI TOTAL PRODUCTIVITY MAINTENANCE (TPM)

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  1. IMPLEMENTASI TOTAL PRODUCTIVITY MAINTENANCE(TPM) Nazaruddin Nazaruddin

  2. 1. Productivity Management; proses manajemen formal yg menyertakan semua tingkatan manajemen dan kartyawan dengan sasaran akahir mengurangi ongkos pabrikasi, distribusi dan penjualan suatu produk/jasa melalui suatu pengintegrasian empat tahap siklus produktivitas (MEPI) Ada 2 metode pengukuran produktivitas (Sumanth, 1984): 2. Productivity Engineering; terkait dengan disain, pemeliharaan dan pengembangan pengukuran produktivitas, evaluasi, perencanaan, dan sistem peningkatan dalam organisasi pabrikasi dan jasa Kebijakan keuangan UGM

  3. Nakajima (1988); productivity engineering ≈ Total Productivity Maintenance melalui pengukuran Overall Equipments Effectiveness (OEE) W. Mark & M. Nakamura (1997); “ TPM is an activity/partnership between maintennace and production organisations to improve product quality, reduce waste, reduce manufacturing cost, increase equipment availability and improve a company’s overall state of maintenance” Nazaruddin

  4. Equipments Six Big Losses Calculation of Overall Equipments Effectiveness Loading time • Equipment • Failure Loading time MTBF Availability = -------------------------------- MTBF + MTTR + MWT Downtime Losses 2. Setup & Adjustment Net Operating Time 3. Idling & Minor Stoppages Speed Losses (Total Pieces/Operating Time) Performance = ------------------------------------------ Efficiency Theoritical O/T 4. Reduced Speed Valuable Operating Time Defect Losses 5. Defects in Process Processed amount – Defect amount Rate of Quality = --------------------------------------- Products Processed amount 6. Reduced Yield OVERALL EQUIPMENTS EFFECTIVENESS = Availability x Performance Eff x Rate of Quality Nazaruddin

  5. MTBF : Mean Time Between Failure (expectation of production time between failures) MTTR : Mean Time To Repair (expectation of time to restoration) MWT : Mean Waiting Time (expectation of time for restoration to statr) Ket: OVERALL EQUIPMENTS EFFECTIVENESS (OEE) = Availability x Performance x Rate of Quality Avaibility; pengukuran kehandalan mesin yang diukur dari waktu terbuang (downtime loss) pada Saat mesin utama sedang beroperasi, sedangkan Performance Efficiency Mengukur ouput selama waktu yang tersedia (actual cycle time) dibandingkan dengan kapasitas terpasang (theoretical cycle time) dan Quality Rate mengukur tingkat ouput produk bagus dibandingkan dengan jumlah produk gagal Nazaruddin

  6. Nazaruddin

  7. Contoh Aplikasi: PT. CP merupakan salah satu produsen pakan ternak yang memproduksi makanan ternak untuk ikan. Aliran proses produksi dapat dilihat pada diagram berikut ini. Raw Material Coarse Grinding Dry Mixing Fine Grinding Wet Mixing Finish Goods Packaging Cooling Pelletizing (sinking feed) Finish Goods Packaging cooling Drying Extrution (floating feed) Nazaruddin

  8. Nazaruddin

  9. Kapasitas pakan tenggelam (sinking) berdasarkan kapasitas Mesin Pellet Mill Kapasitas pakan terapung (floating) berdasarkan kapasitas Mesin Extruder Data produksi tahun 2006 untuk Mesin Pellet 1 adalah sbb: Nazaruddin

  10. Lakukan analisis terhadap TPM Mesin Pellet tersebut (data tambahan) Nazaruddin

  11. See you next time Nazaruddin

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