Improvement of Ribbed Smoked Sheet (RSS) Production Effectiveness and Efficiency Using Total Productive Maintenance (TPM) Concept on Sheeter Machine

Abstract

This study aims to measure the sheeter machine's effectiveness, efficiency, and decline factors. Also, recommendations for improvement are made to counteract the decrease in RSS production efficiency. Overall Equipment Effectiveness (OEE) and Total Equipment Efficiency (TEE) were used to measure the effectiveness and efficiency of the machine. The Failure Method Effect Analyze (FMEA) is used to investigate machine failure, while TPM provides recommendations for improvement. The results showed that the sheeter machine effectiveness value in one year was almost entirely above the international standard at 85%, except for April and May at 72.27% and 80.33%. Furthermore, the highest and lowest TEE value was in February and April with 86.29% and 58.11%, respectively. According to the Six Big Losses calculations, the causes of a decrease in the effectiveness and efficiency of the sheeter machine were breakdown, setup, and adjustment losses, and idling, and minor stoppages. The failures with the highest Risk Priority Number (RPN) based on the FMEA were rusty bearings and halted machines resulting from tucked sheets under the roller. Minimizing Six Big Losses and adopting an autonomous maintenance system were two recommendations based on the TPM concept for increasing the efficacy and efficiency of RSS manufacturing.