Artikel ini disumbangkan oleh Bapak Estu Widodo [
[email protected]] Kalau ingin belajar bisnis dan manajemen produksi/operasi, silahkan kirim email ke:
[email protected] atau berkunjung ke web http://finance.groups.yahoo.com/group/APICS-ID/ Berkunjung ke web lebih dianjurkan untuk mempercepat proses pendaftaran Informasi lebih lanjut bisa didapat dengan berkunjung ke: 1. Indonesian Production Production and Operations Management Society (IPOMS). http://www.ipoms.or.id/mambo 2. http://www.clt.astate.edu/asyamil/ ==================================================== TPM TOTAL PRODUCTIVE MAINTENANCE
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SEJARAH TPM - Dikenalkan di Jepang oleh Seichi Nakajima - Dikembangkan dari Preventive Maintenance System dari U SA - Perkembangan dari TPM bisa di rinci atas 4 tahap Breakdown Maintenance tahun 1950 han o o Preventive Maintenance tahun 1960 han Predictive Maintenance tahun 1970 han o TPM o Maksud TOTAL dalam TPM : 1. Total berate melibatkan keseluruhan karyawan 2. Total berarti melakukan dengan benar dan effective 3. Total berarti Maintenance System yang meliputi : a. Preventive Maintenance (PM) b. Maintenance and Maintenability c. Maintenance Prevention (MP) d. Maintenability Improvement (MI)
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TIGA FASE DAN DUABELAS LANGKAH PENERAPAN TPM FASE 1. PERSIAPAN 1. Top Management mengumumkan keputusan mengenalkan TPM 2. Launching training dan kampanye TPM untuk middle level 3. Membuat organisasi untuk promosi TPM 4. Menerapkan dasar kebijakan TPM dan TPM objective 5. Merumuskan program untuk pengembangan TPM 6. TPM kick off FASE 2. PENERAPAN TPM 7. Improve effectiveness pada setiap peralatan 8. Mengembangkan program autonomous maintenance 9. Mengembangkan program schedule maintenance 10. Mengadakan training untuk mengimprove operasi dan skill maintenance 11. Mengembangkan Early Equipment Management Program
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CONTOH MASTER PLAN : 1979 prepare
s t s n e e n m e v p i t i u c e q f E f E
e c n a n e t n i a M s u o m o n o t u
1980 implement
introduce
1981 complete
stabilize
1982 improve maintenance
Create model line through group activities Step to prevent suddent braek down. Preventive Maintenance
Reduce Set Up/ Adjustment time
Reduce breakdown of parts
Build foundation for Autonomous Maintenance Promote Autonomous Maintenance 1. Initial Cleaning 2. Solve Difficult Problem 3. Cleaning/ Lubricating Std 4. General Inspection
5. Re Evaluate step 2 & 4 6. Self Audit 7. Organization/ Tidiness 8. Goal Management
t n e m n o r i v n e g n i k r o w e l l e b v r e a l o v g a n i f n a n g i n w - i e t a z r e i
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CONTOH TPM GOAL
NO
ITEM
CURRENTLY
GOAL
1 2 3 4 5 6 7 8 9 10 11
Reduce failure Reduce equipment failure rate Reduce incident of serious equipment failure Reduce non operating time Increase operating rate of equipment Increase productivity Reduce defect in process Conserve Energy Increase number of equipment suggested Reduce accident Increase safety rate
938/ mo 1.03 case/ 100 hr 1.59% 5800 hr/ mo 88.88% 113% 0.7% 100% (1977) 2.1/ yr/ person 14.05 cases/ 1 mil hr 0.80 days/ 1000 hr
less than 50/ mo less than 0.2 case / 100 hr less than 0.4 % under 2900 hr/ mo (reduce 50%) more than 95% more than 141 % (increase 25%) less than 0.35 % less than 77% (used 1980) 10/yr per person 7 cases/ 1 mil hr 0.03 days/ 1000 hr
8/81 Result of TPM will be evaluated by the PM prize committee (when the company consider for the prize)
OBJECTIVE DEPLOYMENT :
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LIMA AKTIVITAS TPM : 1. Memaksimalkan OEE (step 7) 2. Autonomous Maintenance (step 8) 3. Preventive Maintenance System (step 9) 4. Meningkatkan Skill Personal dan Training (step 10) 5. Initial Equipment Management (step 11)
1. -
Memaksimalkan OEE (step 7) Aktifitas utama TPM adalah meningkatkan OEE Hasilnya diukur dengan nilai OEE dalam persen OEE = Down Time x Speed Losses x Quality Yield Untuk mencapai OEE yang bagus dengan cara menghilangkan 6 losses. ENAM LOSSES o Down Time, rusak set up o Speed Losses, idle, setting, adjustment, kerusakan kecil
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Equipment
Six Big Loss
Calculation of OEE
Loading Time LT) Operating Time
1 ) e T Equipment Failure m i D T ( s n e 2 w s Set Up & o s o D L Addustment
LT - DT Availability =
x 100% LT
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2. Autonomous Maintenance (step 8) Operator bertanggung jawab untuk merawat mesin dengan melakukan pengecekan harian, pelumasan, pengukuran dan tugas maintenance lainya. TUJU LANGKAH UNTUK MENGEMBANGKAN AUTONOMOUS MAINTENANCE ; 1. Initial cleaning 2. Eliminasi sumber kontaminasi dan bagian yang tidak terjangkau 3. Mengembangkan dan merawat cleaning dan standard lubrikasi.
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7. Penerapan program autonomous maintenance - Fokus pada penghilangan enam losses - Promote audit untuk autonomous maintenance system VISUAL KONTROL SEBAGAI TOOL YANG MEMBANTU PENERAPAN AUTONOMOUS MAINTENANCE : - Tujuan visual control adalah, sekali melihat langsung mengetahui kondisinya. - Seeing is believing
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Contoh contingency Plan : Section : ……….. Scope of Contigency Plan : Breakdown of finishing grinding machine on journal and pin Breakdown of journal and pin milling machine Breakdown of lapping machine Rute of approval Production foreman
Maintenancefore man
Check by Prod & Mtc Spv
Aproval by Factory Manager
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o
Maintenance Prevention Design Tujuannya mencegah breakdown dan defect untuk instalasi dan peralatan baru dengan menerapkan preventive maintenance yang baik Hal ini juga termasuk memberikan masukan kepada produsen mesin dengan informasi dari mesin sebelumnya.
AKTIVITAS GROUP KECIL.
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