Evaluation of Total Productive Maintenance Implementation in PT Semen Padang

Safina, Firda (2020) Evaluation of Total Productive Maintenance Implementation in PT Semen Padang. Diploma thesis, Universitas Andalas.

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Abstract

One of the supporting factors for the success of a manufacturing industry is determined by the smooth production process. If the production process is smooth, then the use of machinery and production equipment will produce the quality products meet the production schedule, and reduce the production costs. Therefore, it is needed an appropriate maintenance to achieve the smooth production. PT Semen Padang is one of the manufacturing companies in the Padang city that produces cement as the main product. In order to win the competition, more advanced and consistent methods and actions are needed to face the competitors. One of strategy is by applying the Total Productive Maintenance (TPM) in the production line. In order to evaluate the TPM implementation, PT Semen Padang has calculated the Overall Equipment Effectiveness (OEE) value. If the actual OEE higher than the target OEE, then it is concluded that TPM has well implemented. And vice versa if the actual OEE is lower than the target OEE, then it is concluded that the TPM has not been well implemented. The objectives of this research are to evaluate the TPM implementation on AM pillar and propose the improvements to the TPM implementation in PT Semen Padang. The research begins with the identification of Key Performance Indicators (KPIs) based on the 7 Autonomous Maintenance Steps mostly and adjusts to several related journals in order to obtained the initial KPIs, then the KPIs validation process that resulted in proposed KPIs. Furthermore, the design of a pairwise comparison questionnaire using the Saaty Scale which aims to determine the importance weight of KPIs using the Analytic Hierarchy Process (AHP) method. Then design and validation process of evaluation instrument for TPM implementation on AM pillar is conducted. Next, the assessment of TPM implementation on AM pillar in Indarung IV plant of PT Semen Padang. Finally, calculating the value each indicators of KPIs and calculating the performance index for TPM implementation on AM pillar in Indarung IV plant of PT Semen Padang using Objective Matrix (OMAX) method. The results obtained are performance index and proposed improvement to the TPM implementation on AM pillar in Indarung IV plant of PT Semen Padang. Performance index obtained is 6.60 which is in the yellow zone colour of the Traffic Light System (TLS). The improvement suggestions is proposed to the indicators of KPIs that has improvement priority based of the TLS concept and AHP method. One of indicators that improved is indicator of the number of abnormalities that found. The improvement suggestion is development One Point Lesson (OPL) and tag card for abnormalities. Keywords : Total Productive Maintenance, Autonomous Maintenance, Overall Equipment Effectiveness, Analytical Hierarchy Process, Objective Matrix, Traffic Light System, PT Semen Padang

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