Implementasi TPM (Pilar Planned Maintenance) untuk Perawatan Pada Mesin Crusher Keramik Di PT XY

Hardianto, Michael Errico (2026) Implementasi TPM (Pilar Planned Maintenance) untuk Perawatan Pada Mesin Crusher Keramik Di PT XY. S1 thesis, Universitas Kristen Indonesia.

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Abstract

Mesin crusher keramik di PT XY memiliki peran penting dalam proses pengolahan limbah keramik reject agar dapat dimanfaatkan kembali sebagai bahan baku. Namun, pada kondisi awal penelitian, kinerja mesin crusher belum optimal yang ditunjukkan oleh tingginya downtime dan rendahnya efektivitas mesin. Permasalahan utama yang dihadapi adalah sistem perawatan yang masih bersifat reaktif (breakdown maintenance), sehingga sering terjadi kerusakan mendadak yang berdampak pada penurunan produktivitas. Penelitian ini bertujuan untuk menganalisis efektivitas mesin crusher menggunakan metode Overall Equipment Effectiveness (OEE) serta merancang dan mengimplementasikan Total Productive Maintenance (TPM) pilar Planned Maintenance guna meningkatkan kinerja mesin. Metode penelitian yang digunakan meliputi pengumpulan data downtime, waktu operasi, dan output produksi, perhitungan nilai availability, performance rate, dan quality rate, serta analisis penyebab kerugian menggunakan fishbone. Selanjutnya, dilakukan penyusunan jadwal Planned Maintenance berupa inspeksi, pelumasan, pembersihan, dan penggantian komponen kritis secara terencana. Hasil penelitian menunjukkan bahwa sebelum implementasi Planned Maintenance, nilai availability mesin crusher sebesar 73%, performance rate sebesar 58,6%, dan quality rate sebesar 99.84%, sehingga diperoleh nilai OEE sebesar sekitar 43.9%. Nilai ini masih jauh di bawah standar world class OEE sebesar 85%. Setelah implementasi TPM pilar Planned Maintenance, terjadi peningkatan signifikan pada kinerja mesin, di mana nilai availability meningkat menjadi 93%, performance rate menjadi 75,6%, dan quality rate tetap sebesar 99,91%. Dengan demikian, nilai OEE rata-rata aktual setelah implementasi meningkat menjadi 70,8%. Peningkatan nilai OEE tersebut menunjukkan bahwa penerapan Planned Maintenance mampu menurunkan downtime dan breakdown mesin secara signifikan serta meningkatkan stabilitas operasi mesin crusher. Meskipun demikian, nilai OEE yang dicapai masih belum memenuhi standar world class OEE, sehingga diperlukan penguatan melalui integrasi pilar TPM lainnya seperti Autonomous Maintenance, Focused Improvement (Kaizen), serta peningkatan kompetensi sumber daya manusia. Dengan penerapan TPM secara berkelanjutan, diharapkan efektivitas mesin crusher dapat terus meningkat dan mendukung produktivitas perusahaan secara optimal. Kata kunci: Total Productive Maintenance, Planned Maintenance, Overall Equipment Effectiveness, OEE, Mesin Crusher. / The ceramic crusher machine at PT XY plays an important role in processing rejected ceramic waste so that it can be reused as raw material. However, under the initial condition of the study, the performance of the crusher machine was not optimal, as indicated by high downtime and low machine effectiveness. The main problem identified was a maintenance system that was still reactive in nature (breakdown maintenance), which resulted in frequent unexpected failures and reduced productivity. This study aims to analyze the effectiveness of the crusher machine using the Overall Equipment Effectiveness (OEE) method and to design and implement Total Productive Maintenance (TPM) through the Planned Maintenance pillar in order to improve machine performance. The research methodology includes data collection of downtime, operating time, and production output; calculation of availability, performance rate, and quality rate; and analysis of loss factors using Pareto and fishbone diagrams. Furthermore, a Planned Maintenance schedule consisting of inspection, lubrication, cleaning, and scheduled replacement of critical components was developed and implemented. The results show that before the implementation of Planned Maintenance, the crusher machine had an availability of 73%, a performance rate of 58.6%, and a quality rate of 99.84%, resulting in an OEE value of approximately 43.9%. This value was significantly below the world-class OEE standard of 85%. After the implementation of the TPM Planned Maintenance pillar, machine performance improved considerably, with availability increasing to 93%, performance rate rising to 75.6%, and quality rate remaining at 99.91%. Consequently, the average actual OEE after implementation increased to 70.8%. The increase in OEE indicates that the implementation of Planned Maintenance successfully reduced machine downtime and breakdowns while improving operational stability. Nevertheless, the achieved OEE value has not yet met the world-class standard, indicating the need for further improvement through the integration of other TPM pillars such as Autonomous Maintenance, Focused Improvement (Kaizen), and continuous training of human resources. The sustainable implementation of TPM is expected to further enhance the effectiveness of the crusher machine and support optimal company productivity. Keywords: Total Productive Maintenance, Planned Maintenance, Overall Equipment Effectiveness, OEE, Crusher Machine

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