Adapting OEE and Total Productive Maintenance (TPM) to Improve Machine Performance

Subject Areas : Maintenance Planning

Rendiyatna Ferdian ^{1 *} , Didit Damur Rochman ² , Tiaradia Ihsan ³

1 - Department of Industrial Engineering, Widyatama University, Bandung, Indonesia
2 - Department of Industrial Engineering, Widyatama University, Bandung, Indonesia
3 - Department of Industrial Engineering, Widyatama University, Bandung, Indonesia

Received: 2025-09-02 Accepted : 2025-10-16 Published : 2025-11-10

Keywords: Improve, Manufacturing, Milling Machine, Overall Equipment Effectiveness (OEE), Total Productive Maintenance (TPM),

Abstract :

This study aims to evaluate the effectiveness of milling machines at PT X, a strategic defense and security equipment manufacturer in Indonesia, by adapting the Overall Equipment Effectiveness (OEE) and Total Productive Maintenance (TPM). The purpose of this research is to identify key factors contributing to production inefficiencies, and to propose improvement strategies. The methodology employed combines direct observation, production log analysis, and structured interviews with operators and supervisors. Data collection focused on three key dimensions of OEE: availability, performanceand quality. Data were cross-verified with machine logbooks and operator feedback to ensure accuracy. OEE values were calculated, and the Six Big Losses framework was applied to pinpoint the major sources of inefficiency. The findings revealed that the average OEE of the milling machine was 47.65%, significantly below the industry benchmark of 85%. Availability remained relatively high at 96.12%, but performance and quality lagged, with a 25.28% rejection/rework rate and frequent minor stoppages contributing to prolonged cycle times. Speed Losses and Quality Losses were identified as the most critical issues, including up to 41.95% idle time in certain months and a defect rate of 18.63%. The study concludes that PT X must prioritize productive maintenance, supported by gradual and realistic implementation steps, to reduce unplanned downtime and improve machine performance. Additional strategies include automation of setup processes, enhanced quality control mechanisms, operator training, and real-time monitoring systems. By adopting these measures, PT X can improve OEE, reduce production costs, and strengthen its competitiveness in the manufacturing sector.

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