Professional Documents
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MTC - Materi Dojo SPV2
MTC - Materi Dojo SPV2
INPUT
INPUT PROCESS
PROCESS OUTPUT
OUTPUT
PRODUCTION PROCESS
ASSET
Availability
DATABASE OEE
OEE (%)
(%) Performance
Quality
TOOLS
TOOLS PM
LINE
LINE STOP
STOP (%)
(%) Zero Breakdown
Control and
CORRECTIVE Manage
EQUIPMEN
EQUIPMEN Maintenance
TT Operations
To make production MTTR
MTTR (minutes)
(minutes) Repair time
Company asset PREDICTIVE
Process running well
FACILITY
FACILITY With good equipment
BREAK DOWN Equipment
MTBF
MTBF (hour)
(hour)
durability
PROBLEM
PROBLEM SPARE PARTS
SHEET
SHEET
CONFIDENTIAL |
Operations IKP Maintenance
MAINTENANCE OPERATION PLANT PERFORMANCE
CONTROL INDICATOR
DATABASE EQUIPMENT
- Total and status asset equipment at IAMI
DATABASE <new>
SPARE PARTS - List up spare parts requirement and 1. Equipment (Availability)
OEE
OEE
DATABASE replacement schedule regularly 2. Production (Performance)
(75%)
(75%) 3. DRR (Quality)
PREVENTIVE
PM Auto reminder for Preventive
SCHEDULE
Maintenance schedule and parts
PARTS REPLACEMENT replacement regularly
Equipment break down during
CORRECTIVE PROBLEM INDICATED Request sheet, problem sheet, tag TPM, LINE
LINE STOP
STOP production process should be
daily check as first information of (0.17%)
(0.17%) lower than target
HISTORY PROBLEM problem indication to make quick action
Step 3 – Standardize
Step 1 – Clean up
4
3
2
Step 0 – Kick Off
1
f. TPM Organization Chart in IKP h. TPM Activities in IKP
S tee ring com m ittee Mr. Rodko Purba &
Mr. Y. Yamazaki
Mr. Syafi Maulana Mr. Syafi Maulana Mr. Nana Mulyana Mr. Imam Santosa Mr. Nanda G Mr. Hermawan P
S ec tion PM Circ le Body Shop TCF Quality Control Body,GA,Workshop & PPIC POA
Storage
Mr. Daniel Mr. Siswanto Mr. Aringga D Mr. Mujiman Mr. Ario Wibowo
Mr. Rian W
Painting TCAB PPIC
Paint
Mr. Andrew S Mr. Iman Mr. Ahmad Musri
Mr. Danang A/ Mr.
Imam Allif
GAO & Utility
Definition
Pelaksanaan TPM
Genba Shop / MTC
Preventive MTC
Abnormality Report • Problem Sheet made by MTC Shop (Body, Paint, GAO)
• If repair need additional material / spare part(s)
YES
• If repair do not need additional item, no need to make
Melakukan
Menemukan
Pengecekan
Abnormality?
Equipment Problem Sheet
Document
NO
Amri 02-Feb-20
Globe Valve
Tim Produksi Catalogue No : E290A793
DN/Size : 20 mm , G 3/4"
Memeriksa Hasil NC Inlet Port 2 Pcs : 16 Bar
Medium : Air Water Oil Dp : 6 Bar +165°C
Temperature : -10 ~ +184°C
Temperature Ambien : -10 ~ +60°C
Pilot : Air/Water 4 ~ 10 Bar
YES
STATUS
Analisa Penentuan Penanggulangan Pelaksanaan Selesai
Cleaning dan 5S
ϭϲ ͗ Ϭϱ – ϭϲ ͗ ϭϱ
Menemukan Melakukan
YES
Yellow Tag Pengecekan
TPM? Equipment
Cek Equipment
ϭϲ ͗ ϭϱ – ϭϲ ͗ Ϯϱ NO
Membuat Problem
Memerlukan YES
Sheet (ATPPM)
YES NO Memasang Spare Part?
Menemukan
Bisa Self Repair? Yellow TPM Tag
Abnormality?
NO
NO YES
Memasang
TPM Melakukan
Blue TPM Tag
Assessment Perbaikan
NO
Hasil Sudah OK?
YES
Done
10/16/2021
Request Sheet CONFIDENTIAL |
Request Sheet
Definition
Equipment Genba Kaizen Idea
Confirmation
• Request Sheet made by Dept. outside
Making RS Copy
Do Equipment MTC (Prod, PPIC, PPE, etc.)
Addition/
Equipment and Red Tag
•
Modification
Addition and
Modification
If there are addition or/and
Discussion and
Report Progress modification to equipment.
YES to Related Dept.
Repair to Decision to
Request? Addition/ • Discussion and decision process to
Modification
NO
Implement Self
Result OK?
NO
Addition or Modification is important.
Addition/
Modification YES
Make Request
Sheet (RS)
Accept Request
Sheet Copy and
Red Tag
Confirm Result to
MTC
Sign on RS
Dept
UTL - 001
Operator GL
- II/2017
FM Request Sheet - Document CONFIDENTIAL |
Maintenance
Request Sheet Amri
Nugroho
Agun
Gunawan
Eko Puji S
TCF-CAB
2. Seal yang rusak sehingga menyebabkan kebocoran angin Discussion
【Desired repair / countermeasure contents】
Regulator Bocor
1. Explanation defective equipment, desired
Contoh foto alat yang mengalami
【In charge】
【Repair / countermeasure contents】 / /
date.
2
【Scheduled of completion date】 【In charge】 sign
/ /
/ /
date, countermeasure strategy.
3
【Countermeasure person】 【Requestor】
Change record
Date sign content Date sign Content
*Sign is department issuing
1 4
/
/
/ 5
/
/
/
/
Document
3
/ / 6
/ / Refer to Fukuda-san Concept
Problem Sheet VS Request Sheet CONFIDENTIAL |
• Equipment Failure
When Needed • Equipment Repair Need Spare Equipment Addition / Modification
Part(s)
PIC MTC Shop and MTE MTE, MTC Shop, and Requester
(Shop Outside MTC)
10/16/2021
Overall Equipment Effectiveness (OEE)
CONFIDENTIAL |
10/16/2021
Six Big Losses
CONFIDENTIAL |
One of the major goals of TPM and OEE programs is to reduce and/or eliminate what are called
the Six Big Losses – the most common causes of equipment-based productivity loss in
manufacturing.
10/16/2021
OEE Calculation
CONFIDENTIAL |
OEE = A x P x Q
𝑀𝑜𝑑𝑖𝑓𝑦
(𝑃𝑙𝑎𝑛𝑛𝑒𝑑 𝑃𝑟𝑜𝑑 . 𝑇𝑖𝑚𝑒 − 𝑆𝑡𝑜𝑝𝑇𝑖𝑚𝑒 ) 𝑀𝑇𝐵𝐹
A ∑ 𝑥
𝐵 𝑜𝑑𝑦 𝑃𝑙𝑎𝑛𝑛𝑒𝑑 𝑃𝑟𝑜𝑑 .𝑇𝑖𝑚𝑒 (𝑀𝑇𝐵𝐹 +𝑀𝑇𝑇𝑅)
𝑀𝑜𝑑𝑖𝑓𝑦
(𝑇𝑎𝑐𝑡 𝑇𝑖𝑚𝑒 ×𝑇𝑜𝑡𝑎𝑙 𝑂𝑢𝑡𝑝𝑢𝑡 𝑈𝑛𝑖𝑡)
P ∑ (𝑃𝑙𝑎𝑛𝑛𝑒𝑑 𝑃𝑟𝑜𝑑 . 𝑇𝑖𝑚𝑒 − 𝑆𝑡𝑜𝑝𝑇𝑖𝑚𝑒 )
𝐵 𝑜𝑑𝑦
𝑀𝑜𝑑𝑖𝑓𝑦
𝑇𝑜𝑡𝑎𝑙 𝑈𝑛𝑖𝑡 𝑂𝐾
Q ∑ 𝑇𝑜𝑡𝑎𝑙 𝑂𝑢𝑡𝑝𝑢𝑡 𝑈𝑛𝑖𝑡
𝐵 𝑜𝑑𝑦
10/16/2021