CONFIDENTIAL |

Operations IKP Maintenance

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

PREDICTIVE PERIODICALLY CHECK

MTTR
MTTR Increase skill up maintenance
Periodical check critical equipment and repair method to solve the
PROBLEM INDICATED (Max.
(Max. 22
22
analyze to prevent break down equipment problem quickly
minutes)
minutes)
HISTORY PROBLEM

BREAK DOWN EQUIPMENT FAILURE Maintenance performance indicator

to keep zero break down equipment MTBF
MTBF Long life equipment durability
HISTORY PROBLEM Good equipment performance
(Min.
(Min. 420
420 hour)
hour)
SPARE PARTS AVAILABILITY To control availability parts in warehouse
for equipment requirement and
ORDERING TIMING matched with budget allocation in ordering
 CONFIDENTIAL |
a. Definition c. Implementation of the Pillars in 7 Step

b. 8 Pillar of TPM d. Roles in TPM Process

 CONFIDENTIAL |
e. Implementation TPM Step by Step in IKP g. Sustainment of TPM
Step 4 – TPM be habit

Step 3 – Standardize

Step 2 – Find the difficulty

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. Ujang Aziz

Departe m en PM Circle BPO GAO Quality Control Maintenance PPIC POA

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

Mr. Eko Puji

 Operation Rules (Simplified)
Problem Sheet CONFIDENTIAL |

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

No. Dokumen : FORM/J/43/001

YES
Membuat Problem PROBLEM SHEET Tanggal Efektif : 1 Agustus 2017
Memerlukan
Sheet (ATPPM) (ANALISA TINDAKAN PERBAIKAN dan PENCEGAHAN MASALAH) Revisi :1
Spare Part? IS UZ U KAR AWANG P L ANT Department : Maintenance
Maintenance Dept. Control No: UTILITY/01/PS/X/2020 Shop : Utility
TARGET / STATUS /
NO DETAIL MASALAH ANALISA PENYEBAB ( 4M+1E ) TINDAKAN PERBAIKAN dan PENCEGAHAN MASALAH PIC
SCHEDULE EVALUASI
NO 13 Januari 2020

Solenoid Valve Bypass ( Air Water LT Oil )

Merk : ASCO
WH MTC Catalogue No : SCXG356B001VMS
Melakukan
Memberikan Spare Temperature : -10 ~ +60°C
Perbaikan Pipe : G1/8
Part
Power : AC 4 ; DC 6.9
Orif : 12
1

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

Unit GA Compressor no.2

Low oil pressure ,
setelah dicek , ternyata Solenoid Valve Tidak berfungsi
Part Specs.
TARGET / STATUS /
NO No HADOME DESKRIPSI KAIZEN / IMPROVEMENT BEFORE AFTER PIC
Hasil Sudah OK? SCHEDULE EVALUASI

YES

STATUS
Analisa Penentuan Penanggulangan Pelaksanaan Selesai

Dibuat Diperiksa Disetujui Diketahui CATATAN : Diterima

Done Mohon untuk di order

10/16/2021 Solenoid valve & Globe valve

Qty : @ 1 Unit
Operator Foreman Supervisor Kadept Admin MTE SPV MTE
 TPM and Problem Sheet CONFIDENTIAL |

Mulai Genba Shop / MTC Equipment Trouble

Pelaksanaan TPM
Jumat 16:05 Preventive MTC Report

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

Finalisasi Tim Produksi

ϭϲ ͗ Ϯϱ – ϭϲ ͗ ϯ Ϭ Memeriksa Hasil

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

Attach Red Tag

near to Actual
Equipment

Confirm Result to
MTC

Sign on RS

Done Operation Rules (Simplified)

10/16/2021
Refer to Fukuda-san Concept
 Document No: Control No

Dept
UTL - 001
Operator GL
- II/2017
FM Request Sheet - Document CONFIDENTIAL |

Maintenance
Request Sheet Amri
Nugroho
Agun
Gunawan
Eko Puji S

Title Penanggulangan kebocoran angin di GA Shop

Ｒｅｐａｉｒ Explanation
Kaizen

Request／Answer • Fill by Requester

comment
Date of issue / 22-Feb-17
【Desire】 【Defective content】 • Fill by MTC Shop based on
1. Coupler yang rusak sehingga menyebabkan kebocoran angin
【In charge】

TCF-CAB
2. Seal yang rusak sehingga menyebabkan kebocoran angin Discussion
【Desired repair / countermeasure contents】

~ Penggantian coupler dan penggantian

《photo》 • Fill together (Requester and MTC
seal yang rusak, sehingga kebocoran 1 Shop)
tidak terjadi lagi

Regulator Bocor
1. Explanation defective equipment, desired
Contoh foto alat yang mengalami

repair/countermeasure, actual condition

kebocoran angin
Coupler Bocor

【Requested completion date】

Jul-17
documentation, and requested completion
【Answer】 【Answer】 【Date of recipt】

【In charge】
【Repair / countermeasure contents】 / /
date.

2
【Scheduled of completion date】 【In charge】 sign

/ /

【Complet】【Countermeasure completion report】 【 Completed Comment】

2. [Based on Discussion] scheduled completion
【 Completion date】

/ /
date, countermeasure strategy.
3
【Countermeasure person】 【Requestor】

Change record
Date sign content Date sign Content
*Sign is department issuing
1 4

10/16/2021 *Making a request copy and keep

2
/

/
/

/ 5
/

/
/

/
Document
3
/ / 6
/ / Refer to Fukuda-san Concept
 Problem Sheet VS Request Sheet CONFIDENTIAL |

Parameter Problem Sheet Request Sheet

Maker MTC Each Shop Dept/Shop Outside MTC

• Equipment Failure
When Needed • Equipment Repair Need Spare Equipment Addition / Modification
Part(s)

Document Unique Detailed Part(s) Specification Discussion and Decision for

Item Countermeasure

PIC MTC Shop and MTE MTE, MTC Shop, and Requester
(Shop Outside MTC)

10/16/2021
 Overall Equipment Effectiveness (OEE)
CONFIDENTIAL |

All Time (24/7)

Every minute, every day
Time when Plant is not scheduled
for Production. E.g. Plant
Planned Production Time Schedule Loss Shutdown, Break/Lunch, *TPM,
QC Check, Safety Meeting, KYT,
*Schedule Loss is excluded from OEE Analysis
etc.
Any events that stopped planned production.
Availability • Unplanned Stops (Equipment Failure, Material
Running Time Loss Shortage)
• Planned Stops (Changeover Time: 2 minutes
check, 5 minutes preparation, wataridori, trial
new CT)

Anything causes manuf. process run less than max.

possible speed when it’s running:
Performance
Net Run Time Loss
• Slow Cycle: cycle that took longer than ideal CT
• Small Stops: production “pause”
• E.g. machine wear, substandard material, miss
feed

Quality Manufactured parts that do not meet quality

Fully Productive Time Loss standards
10/16/2021 • Parts that need rework
 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