WICAKSONO, HERLANGGA ADHI (2026) OPTIMASI PERFORMA MESIN SCREW COMPRESSOR MELALUI IMPLEMENTASI TOTAL PRODUCTIVE MAINTENANCE. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
The implementation of Total Productive Maintenance (TPM) on a screw compressor machine in a garment manufacturing company has been carried out since the end of 2024; however, its effectiveness in reducing unplanned downtime and maintenance costs had not been comprehensively evaluated. This study aims to assess machine performance after TPM implementation, analyze the effectiveness of TPM in improving operational efficiency, and propose follow-up strategies to sustain maintenance performance. The research employed a case study approach with quantitative methods as the primary analysis using downtime data, failure frequency, and maintenance cost records, supported by qualitative observations and interviews. Prior to TPM implementation, the maintenance system was predominantly reactive, characterized by breakdown maintenance practices, lack of structured scheduling, and minimal operator involvement. After TPM implementation through preventive maintenance, autonomous maintenance, and visual management, machine performance improved significantly, as indicated by reduced operational disturbances, lower downtime, and decreased maintenance costs. In addition to technical and economic benefits, TPM also enhanced operator competency in performing routine inspections and early fault prevention independently. To ensure sustainability, standardization of maintenance schedules, reinforcement of autonomous maintenance checklists, structured recording systems for downtime and maintenance costs, and continuous TPM training for operators are recommended. Overall, TPM has proven effective in improving machine reliability and operational efficiency while supporting workforce capability development within the GA/Estate Department. Keyword: Machine, Screw Compressor, Total Productive Maintenance, Downtime Reduction, Machine Efficiency Penerapan Total Productive Maintenance (TPM) pada mesin screw compressor di perusahaan garmen telah dilaksanakan sejak akhir tahun 2024, namun efektivitasnya dalam menurunkan unplanned downtime dan biaya perawatan belum dianalisis secara komprehensif. Penelitian ini bertujuan untuk mengevaluasi kinerja mesin setelah implementasi TPM, menganalisis efektivitas TPM dalam meningkatkan efisiensi operasional, serta merumuskan rencana tindak lanjut guna menjaga keberlanjutan program perawatan. Metode penelitian yang digunakan adalah studi kasus dengan pendekatan kuantitatif sebagai metode utama melalui analisis data downtime, frekuensi kerusakan, serta biaya perawatan mesin, yang diperkuat dengan observasi lapangan dan wawancara sebagai pendekatan kualitatif pendukung. Hasil penelitian menunjukkan bahwa sebelum penerapan TPM, sistem perawatan masih bersifat reaktif dengan dominasi breakdown maintenance, belum adanya penjadwalan terstruktur, serta minimnya keterlibatan operator dalam aktivitas perawatan. Setelah implementasi TPM melalui preventive maintenance, autonomous maintenance, dan visual management, kinerja mesin menjadi lebih stabil yang ditandai dengan penurunan gangguan operasional, downtime, serta biaya perawatan. Selain memberikan dampak teknis dan ekonomis, penerapan TPM juga meningkatkan kompetensi operator dalam melakukan pemeriksaan dan pencegahan gangguan secara mandiri. Untuk menjaga keberlanjutan hasil implementasi TPM, diperlukan standarisasi jadwal perawatan, penguatan checklist autonomous maintenance, pengelolaan sistem pencatatan downtime dan biaya secara terstruktur, serta pelatihan berkelanjutan bagi operator. Dengan demikian, TPM terbukti mampu meningkatkan keandalan mesin sekaligus efektivitas operasional Departemen GA/Estate. Kata Kunci: Mesin, Screw Compressor, Total Productive Maintenance, Pengurangan Downtime, Efisiensi Mesin
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