TOTAL PRODUCTIVE MAINTENANCE ANALYSIS ON PRINTING MACHINE (A CASE STUDY IN AN INDONESIAN FLEXIBLE PACKAGING MANUFACTURER)

• Main Author: Andrianto Kusumo, Claudius
• Format: Theses
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/65406
• Institution: Institut Teknologi Bandung

PT Kemas Fleksibel is one of the major flexible packaging manufacturer companies in Indonesia. To keep customer satisfaction and stay sustainable in the business, the company has to minimize inefficiency and losses in the production process. Among the three production steps (i.e. printing, laminating, and finishing), the printing process was currently the bottleneck of PT Kemas Fleksibel. The company suffered $410,353 in opportunity loss because of a machine breakdown in the printing section in 2021. To make matters worse, the total machine breakdown duration has been increasing since 2019. As a percentage of available time, the total breakdown duration in the printing section was 2.52% in 2021, significantly higher than 1.65% in 2019. Although the company had implemented some measures of preventive maintenance, the management of PT Kemas Fleksibel was still not satisfied with the result, and improvement was needed. The study used quantitative analysis from the manufacturing report in 2021. The printing process has 68.82% in OEE, which is far lower than world-class manufacturer standards. Among the three aspects of OEE (i.e. availability, performance, and quality), availability is the lowest with 74.45%. The business issue was further explored using the qualitative method by interviews with the relevant stakeholders from Engineering, Production, and Human Resource Departments. The undesirable effects (UDEs) were then logically arranged into a Current Reality Tree (CRT) and the root cause of increasing machine breakdown in the printing section was identified as a lack of regular maintenance evaluation and improvement. To solve the root cause, three alternative solutions were proposed: Planned Maintenance (PM), Autonomous Maintenance (AM), and condition-based maintenance using IoT sensors. Planned Maintenance is thought to be the most effective alternative for improving machine reliability with an estimated 39.05% of breakdown reduction. To determine which alternative to be proposed to the company, the study used Analytic Hierarchy Process (AHP) with five criteria: OEE improvement, human capital improvement, Capex required, Opex required, and ease of implementation. AHP was performed using questionnaires and interviews with the Engineering Manager, Production Manager, and Human Resource Manager. The AHP showed that Planned Maintenance is the preferred alternative with 0.46 point. The company agreed with the proposal and decided to implement Planned Maintenance in the printing machines as a pilot project. The implementation of Planned Maintenance started in the first week of February 2022 with the target of 1.53% in the 2022 breakdown. In the first two months of implementation, the team successfully executed restoring basic conditions in two printing machines, created a maintenance task list, and developed a program for an online machine inspection checklist. At the end of the study, the breakdown in March 2022 was 1.92% and the year-to-date average breakdown in 2022 was reduced to 2.29%. The 1.53% target had not been reached because the project was still in the early stage and Planned Maintenance takes time to materialize its benefits.