Analysis of Total Productive Maintenance (TPM) and Failure Mode and Effect Analysis (FMEA) to improve machine effectiveness: A study on Indonesia's sugar mills

Abstract

Many companies experienced a halt of operation because their production machines are damaged. As a result, customer demand is not fulfilled; such productivity decreases. This study conducted at PT. PG Candi Baru Sidoarjo. They often experience a suffered engine damage on their rolling and grinding station. The purposes of this study were to improve their machine performance at the grinding station by using the Total Productive Maintenance (TPM) and Failure Mode and Effect Analysis (FMEA), to measure the value of Total Productive Maintenance (TPM), and to determine the type of damage that often occurs using the Age Replacement method in order to improve engine maintenance schedule. As the results, the Overall Equipment Effectiveness (OEE) at the grinding station decreased from 2015 to 2016 in the amount of 74.6% to 69.7%. The most frequent types of damage were the IMC chain abrasion, IMC chain breaking, dropping/off track and slip mill. For the type of squashed IMC damage, treatment was carried out on the 12th day at the cost of IDR 3,806,425.92. The dropped/exited IMC from the operation line was repaired on the 13th day at the expense of IDR 5,614,466.88 For the type of rolling slip damage, treatedment done on the 10th day at the cost of IDR 34,272,482.34.