SAPUTRA, YUDA (2026) ANALISIS TOTAL PRODUCTIVE MAINTENANCE (TPM) MENGGUNAKAN METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE) PADA MESIN FILLER PERUSAHAAN MANUFAKTUR MINUMAN DI TANGERANG. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
This study aims to determine the effectiveness of the Filler machine using the Overall Equipment Effectiveness (OEE) method, identify the dominant losses through Six Big Losses analysis, and propose improvement recommendations based on Total Productive Maintenance (TPM) and Single Minute Exchange of Die (SMED) in a beverage manufacturing company in Tangerang. The study was conducted because the Filler machine experienced the highest downtime on the Bottling Line, accounting for 24.38% or 16,150 minutes during the period of March-August 2025. A quantitative research approach was employed using primary data collected through observations, interviews, and questionnaires, as well as secondary data consisting of the company's production and maintenance records. The results indicate that the average Availability Rate, Performance Rate, and Quality Rate were 89.15%, 98.35%, and 98.56%, respectively, resulting in an average OEE value of 86.44%, which exceeds the world class benchmark of 85%. The Six Big Losses analysis revealed that Setup and Adjustment Losses were the most significant losses, with an average value of 4.95%, contributing 37.10% of the total losses. The Cause and Effect diagram identified the root causes as originating from human, machine, method, and material factors. The proposed improvements focus on implementing TPM pillars and the SMED method for the bottle format changeover process by separating internal setup and external setup activities, converting internal setup activities into external setup activities, and streamlining setup operations. The proposed improvements reduced setup time and increased the average OEE value to 87.53%. Keywords: Total Productive Maintenance (TPM), Overall Equipment Effectiveness (OEE), Six Big Losses, Single Minute Exchange of Die (SMED), Filler machine. Penelitian ini bertujuan untuk menghitung tingkat efektivitas mesin Filler menggunakan metode Overall Equipment Effectiveness (OEE), mengidentifikasi jenis kerugian dominan melalui analisis Six Big Losses, serta menyusun usulan perbaikan berdasarkan Total Productive Maintenance (TPM) dan Single Minute Exchange of Die (SMED) pada perusahaan manufaktur minuman di Tangerang. Penelitian dilakukan dikarenakan mesin Filler merupakan mesin dengan tingkat downtime tertinggi pada Bottling Line, yaitu sebesar 24,38% atau 16.150 menit selama periode Maret-Agustus 2025. Penelitian menggunakan pendekatan kuantitatif dengan data primer yang diperoleh melalui observasi, wawancara, dan kuesioner serta data sekunder berupa data produksi dan maintenance perusahaan. Hasil penelitian menunjukkan rata-rata Availability Rate sebesar 89,15%, Performance Rate sebesar 98,35%, dan Quality Rate sebesar 98,56%, sehingga diperoleh rata-rata nilai OEE sebesar 86,44% yang telah memenuhi standar world class sebesar 85%. Analisis Six Big Losses menunjukkan bahwa Setup and Adjustment Losses merupakan kerugian terbesar dengan rata-rata 4,95% atau berkontribusi sebesar 37,10% terhadap keseluruhan losses. Analisis diagram sebab akibat mengidentifikasi akar permasalahan yang berasal dari aspek manusia, mesin, metode, dan material. Usulan perbaikan difokuskan pada penerapan pilar TPM dan metode SMED terhadap aktivitas changeover format bottle melalui pemisahan aktivitas internal setup dan external setup, konversi aktivitas internal setup menjadi external setup, serta penyederhanaan aktivitas setup. Hasil rancangan usulan menunjukkan penurunan waktu setup sehingga meningkatkan rata-rata nilai OEE menjadi 87,53%. Kata Kunci: Total Productive Maintenance (TPM), Overall Equipment Effectiveness (OEE), Six Big Losses, Single Minute Exchange of Die (SMED), mesin Filler.
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