6 big losses total productive maintenance pdf

The concept is a part of total productive maintenance tpm and was developed by seiichi nakajima. A case study in manufacturing industry article pdf available august 2018 with 4,479. Essentra surabaya untuk mengetahui nilai efektivitas. While the factor of six big losses most influential on the low effectiveness of press 2a machine is. Pdf overall equipment effectiveness and the six big losses in.

Equipment failure, setup and adjustments, idling and minor stops, reduced speed, process defects, and reduced yield. Oee is frequently used as a key metric in tpm total productive maintenance and lean. Through the relentless pursuit of overall equipment effectiveness improvement, the tpm cluster has managed to. Total productive maintenance tpm publicinhouse training programme introduction t he evolution of machinery maintenance has progressed from run to failure then to preventive maintenance, predictive maintenance and finally to total productive maintenance tpm, which forms an integral part of a reliability based maintenance. Just like oee, the six big losses have their roots in tpm total productive maintenance. Pdf on apr 1, 2018, okpala charles chikwendu and others published overall equipment effectiveness and the six big losses in total productive maintenance find, read and cite all the research.

Its origin is a maintenance program used in the late 1960s by. Tpm berkembang dari sistem maintenance tradisional yang melibatkan semua departemen dan semua orang ikut berpartisipasi dan mengemban tanggung jawab dalam pemeliharaan mesin. By addressing these losses, a total productive maintenance program results in increased productivity through reduction of wasteful conditions within processes. Implementation using overall equipment effectiveness. One of the major goals of tpm and oee programs is to reduce andor eliminate what are called the six big losses the most common causes of equipmentbased productivity loss in manufacturing first, lets define the six big losses.

It blurs the distinction between the roles of production and. Eliminate production losses due to equipment status, or in other words, keep equipment in a position to produce at maximum capacity, the expected quality products, with no unscheduled stops. Total productive maintenance tpm merupakan pengembangan ide dari productive maintenance adalah metode pemeliharaan mesin dan. Analysis of total productive maintenance tpm implementation using overall equipment effectiveness oee and six big losses. Breakdown loss failure losses losses due to failures. In this prerecorded, live training seminar shot at the peterbilt manufacturing training center in denton, tx, mike wroblewski, a senior lean consultant from gemba consulting and the kaizen institute explains why total productive maintenance tpm is not optional for lean thinking companies who rely on machines and equipment to satisfy customer demand. Keywords total productive maintenance, overall equipment e ffectiveness, six big losses, breakdown. Ftags, the machine history log, and minor stops or unrecorded losses categorizing 63. Pdf analysis of overall equipment effectiveness oee with. American practice of preventive maintenance with total quality control and total employee involvement, to create a culture where operators.

Implementing successful total productive maintenance tpm in a manufacturing plant ignatio madanhire, and charles mbohwa abstract this study examines the impact of total productive maintenance tpm implementation on an organization in terms of productivity and quality levels. Total productive maintenance is an innovative approach to maintenance that optimizes equipment effectiveness, eliminates breakdowns and promotes autonomous maintenance by operators through daytoday activities involving total workforce bhadury, 2000. Mar 05, 2017 tpm total productive maintenance lean management. Ok, the last tpm topic wed like to introduce in this overview module is what we call the 6 big losses. Performance analysis of tpm implementation through overall. Total productive maintenance download ebook pdf, epub. Total productive maintenance program perawatan yang melibatkan semua pihak yang terdapat dalam suatu perusahaan untuk dapat saling bekerja sama dalam. In tpm the machine operator is responsible for the maintenance of the machine, as well as its operation. Dalam meningkatkan efisiensi dan efektivitas perusahaannya, pt. The following table lists the six big losses, and shows how they relate to oee loss categories. Pdf analisis overall equipment effectiveness dalam. Penelitian ini mengambil studi kasus pada mesin cavitec di pt. Seiichi nakajima developed tpm and the six big losses in 1971 while at the japanese institute of plant maintenance.

Productive maintenance carried out by all employees through small group activity. Pdf overall equipment effectiveness and the six big. Pdf on jul 1, 2019, akhmad sutoni and others published total productive maintenance tpm analysis on lathe machines using the overall equipment effectiveness method and six big losses find. An introduction to total productive maintenance tpm j. General stepbystep method for calculating the oee index. Aug, 2012 a quick overview of the six major losses analyzed in tpm.

One of the major goals of tpm and oee programs is to reduce andor eliminate what are called the six big losses the most common causes of equipmentbased productivity loss in manufacturing. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in time etc. Total productive maintenance overview the mission of each pillar is to reduce loss with the ultimate aim of elimination of all losses. How to calculate overall equipment effectiveness oee this is a primaryimportance topic in the total productive maintenance tpm discipline. He characterized maintenance as the responsibility of all employees. Tpm and oee introduction total productive maintenance tpm is defined as a companywide,teambased effort to build quality into equipment and to improve. Seiichi nakajima developed tpm and the six big losses in 1971 while at. Overall equipment effectiveness and the six big losses in total productive.

Pdf total productive maintenance tpm analysis on lathe. Total productive maintenance tpm has its origins in the united states, where many manufacturing companies applied certain pract. Total productive maintenance tpm, a japanese management protocol developed to alleviate production losses caused by machine breakdowns and supporting justintime manufacturing policies, has aroused considerable interest in the western. Japan institute of plant maintenance jipm, the six big losses framework enables. The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment. Tpm total productive maintenance is a holistic approach to equipment maintenance that strives to achieve perfect production. Eliminating the six big losses 28 availability losses 28 performance losses 37 quality losses 40 implementing tpm 43 summary 61. This waste is due to operators, maintenance personal, process, tooling problems and. Total productive maintenance universitas brawijaya. Semen indonesia persero tbk, telah menerapkan total productive maintenance. Its purpose is to maximize availability according to the production schedule, generating products at the highest capacity, according to the expected quality, and without unscheduled stops. The following table shows the six big losses, their relation to oee and typical examples in a production facility.

Tpm emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. Nilai efektivitas yang didapat kemudian dibandingkan. S sebagai rekomendasi perbaikan dengan menggunakan total productive maintenance studi kasus di pt. To start implementation of tpm firstly top management need to understand that tpm needs to be part of a long. One of the most effective paths to improving oee is through the six big losses. The six big losses in lean explained in the light of tpm total productive maintenance and oee overall equipment effectiveness program one of the key objectives is to decrease or get rid of what is known as the six big losses that indicates the most common causes in productivity failures within manufacturing. Namun dalam pelaksanaannya masih belum optimal, yaitu sering terjadinya downtime pada mesin produksinya. Ftags, the machine history log, and minor stops or unrecorded losses categorizing 63 finding out the tpm causes for the ftags to help find the cure 71 pareto charts 80 the defect map 83 chapter 4. Tindakan perbaikan yang diusulkan adalah memprioritaskan 3 pilar utama tpm yaitu autonomous maintenance, quality maintenance, training dan education. The time required to reach normal running condition after a changeover or beginning of the week, or after pm. Beating the six big losses in manufacturing with industry 4. Type of failure include sporadic function stopping failures and function reduction failure in which the function of the equipment drop below normal levels like replacement of parts and repair, cases requiring 5 minute or more for repair. Six big losses, biang keladi buruknya kinerja produksi kang.

Dalam sebuah rapat dibeberapa hari yang lalu, ada seorang pemimpin rapat menyampaikan kata. Six big losses, biang keladi buruknya kinerja produksi. Reduced speed loss with total loss for a year of 56. What is tpm total productive maintenance productivity. In fact, one of the goals of tpm is to eliminate the six big losses. Breakdown losses kerugian breakdown diantaranya kerugian waktu produktifitas menurun, kerugian jumlah karena produk cacat.

Maintenance prevention and maintainability improvement gave birth to productive maintenance. In addition, productivity and quality are better then ever before. Total productive maintenance tpm arises from japan as a system designed to eliminate equipments six big losses related to their condition. Because of electricity, fuel, utility cost represents a high percentage of the total cost, all companies are striving to reduce them. Tpmmanager age posthuma explains this, by stressing three success factors. To achieve perfect manufacturing 0 breakdowns, defects, speed losses. Langkah untuk mencegah atau mengatasi masalah terrsebut dalam usaha. The impact of total productive maintenance on the manufacturing sector by i. Equipment failur kerugian karena kerusakan peralatan. Tpm and oee introduction total productive maintenance tpm is defined as a companywide,teambased effort to build quality into equipment and to improve productivity by reducing the time lost due to breakdowns. The biggest factor that influences the low value of oee is performance rate with percentage factor six big losses at reduced speed losses of 17. Before discussing about oee, let me remind you of some basic principles of tpm.

Analysis of overall equipment effectiveness oee with total productive maintenance method on jig cutting. Rapat itu terdiri dari dua puluhan orang mulai dari karyawan junior hingga senior, memang yang tim rapat utama hanya 10 an orang dan sisanya belasan duduk kebanyakan sebagai pengamat saja, sembari memainkan bb meski rada sembunyisembunyi. The aidc total productive maintenance programme has succeeded in optimising local suppliers towards global levels of competitiveness. Tpm total productive maintenance definition 22 tpm is a team process implemented through specific techniques that systematically eliminates defects and losses due to equipment. Six major equipment losses major stops minor stops changeover loss startup shutdown loss speed loss quality loss definitions major stops any stoppage that is greater than 10 minutes note. Often the challenge lies in determining the root cause and the full extent of. An introduction to total productive maintenance tpm. Total productive maintenance tpm is productive maintenance carried out by all employees through small group activity. Here, in recent years, the overall equipment effectiveness of the packaging lines rose from 47 to 72%. Addressing improving the major loss events of simple oee. Analysis of total productive maintenance tpm implementation. Learn what total productive maintenance tpm is in this overview video duration. Total productive maintenance tpm merupakan pengembangan ide dari productive maintenance adalah metode pemeliharaan mesin dan peralatan mesin.

To keep value flowing, and maximize your sales and margin contribution, you must engage everyone in establishing and maintaining equipment and process reliability. The six big losses originate from the world of total productive main tenance tpm. History of tpm total productive maintenance tpm was first defined in 1971 by the japan institute of plant maintenance jipm. The 6 losses are equipment failure setup and adjustments idling and minor stops reduced speed process defects reduced yield. Achieve zero equipment breakdowns by implementing systems of parts replacement before failure through tbm and cbm. So when we look at those six major losses, we can actually measure them. The six big losses provide an equipmentbased perspective on lost production time. Mabunda 200500185 submitted in partial fulfilment of the requirements for the degree of masters in business administration graduate school of business, faculty of management university of natal durban supervisor. Keywords total productive maintenance, overall equipment effectiveness, six big losses, breakdown. The time from when the last case of a run was produced to the first case of the next run. Six big losses tpm, oee, and improving productivity oee. Proposed improvement actions are the application of autonomous maintenance, providing training for operators and maintenance technicians and supervising operators in the workplace. Tpm is an extension of tqm total quality management.

The brewery of heineken in s hertogenbosch is one of the best production sites, concerning total productive maintenance. Those are the six major losses that we look at and if didnt have those we would be in maintenance heaven. Tujuan penerapan total productive maintenance tpm tujuan daripada tpm total productive maintenance adalah untuk meningkatkan produktivitas pada perlengkapan dan peralatan produksi dengan investasi perawatan yang seperlunya sehingga mencegah terjadi 6 kerugian besar six big losses yaitu. Implementation of total productive maintenance and overall. Tpm improves equipment effectiveness lean production. Tpm was created originally by nakajima over 20 years ago, and still considered today the leading plant. Total productive maintenance tpm originated in japan in 1971 as a method for improved machine availability through better utilization of maintenance and production resources tpm is a maintenance process developed for improving productivity by making processes more reliable and less wasteful. Feb 6, 20 world class oee calculation to total productive maintenance objectives. Analisis penerapan total productive maintenance tpm. Annual maintenance plans equipment total maintenance standards. The six big losses in lean explained latest quality. Reduce six big losses of equipment tpm with the help of. Tpm pillarseight pillars of total productive maintenance.

Capture the six big losses to gain additional actionable insight to the oee factors of availability, performance, and quality. Cayman systems usa 5 7773394 1998 revision a 980810 tpm awareness information 2. Mikes going to introduce a powerful metric called overall equipment effectiveness, or oee, which allows us to quantify the 6 major types of equipment losses. The six big losses originate from the world of total productive maintenance tpm. The implementation of tpm can generate considerable cost savings through increased productivity of the machinery.

By then nippon denso had made quality circles, involving the employees participation. Through the relentless pursuit of overall equipment effectiveness improvement, the tpm cluster has managed to save in excess of r16 million from kick off till august 2014. Planned maintenance start 6 big losses start individual improvement start. Sri rejeki isman tbk, diajukan sebagai salah satu syarat. Implementing successful total productive maintenance tpm in.