Calculation of Overall Equipment Effectiveness Total Productive Maintenance in Improving Productivity of Casting Machines

Volume 4, Issue 7, July – 2019 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Calculation of Overall Equipment Effectiveness Total

Productive Maintenance in Improving Productivity of
Casting Machines
Nila Chandra Sakti, Susiyanti Nurjanah, Erry Rimawan
Magister of Industrial Engineer, Mercu Buana University
Abstract:- In a production process not only about input, which is caused by a decrease in the performance of the
process and output. Its include about maintenance of production machine.
production machines. The maintenance of a production
machines is highly recommended, because it will be This research will focus on die-casting machines,
related with the performance of the machine in where used to produce one of motorcycle spare part.Based
production.The same things works for die casting on data collected about the effectiveness of die casting
machines in one of biggest industry of manufacturing in machines, it shows that this machine has not fully worked
Indonesia where the engine or machines is still not effectively.This is shown by the data downtime, data
operate with normally due downtime happend. Because decreasing engine speed and product defect data.For this
of it all, using the help of the Overall Equipment reason, author do a study of the research engine to measure
Effectiveness (OEE) method for Six Big Loses on this the effectiveness of die casting machines using the Overall
machines we got the big one problem is reduced speed Equipment Effectiveness (OEE) method, and analyze the
loss which is up to 65%. causes of six big losses of die casting machines using
Fishbhone diagrams, and the authors could suggest
Keyword:- Overall Equipment Effectiveness (OEE), Six Big improvements to improve effectiveness die casting
Loses, Die Casting Machines. machine.
I. INTRODUCTION II. RESEARCH METHOD
In manufacturing or non-manufacturing industry, This research consists of several stages of data

maintain is needed for machinery or equipment, work as a processing, the stages of calculating the effectiveness of die
tools of production. Maintenance management is the casting machines using the Overall Equipment
maintene through a process of planning, organizing, and Effectiveness (OEE) method, and the stages of analyzing
controlling operation about industrial facilities. the factors causing Six Big Losses of die casting machines
using the Fishbhone diagram.
In the development thing, there's a new concept of
maintenance managaement, which aims to maintain  Overall Equipment Effectiveness (OEE)
productivity optimization as Total Productive Maintenance OEE is a method that is used as a metric in
(TPM). implementing TPM programs to maintain equipment in
ideal conditions by removing Six Big Losses
Total Productive Maintenance (TPM) is a equipment.OEE measurement is based on the measurement
development of ideas from total productive maintenance of three main ratios, namely (1) Availability ratio, (2)
which is a method for keep or maintain machine and Performance ratio, and (3) Quality ratio. To get an OEE
equipment so the machine can run well when operated. value, the value of the three main ratios must be known in
advance.The Availability ratio is a constellation that
One of the output from Total ProduvtiveMaintenace describes the use of time available for the operation of
(TPM) method is Overall Equipmet Effectiveness (OEE). machinery or equipment. Nakajima (1988) states that
availability is the ratio of operation time, by eliminating
Overall Equipment Effectiveness (OEE),is a ability for equipment downtime, to loading time.The formula for used
identify of root cause and another factor of causes, so it can to measure the availability ratio is:
make us focus with the main factor of damage in machine
or equipment. 𝐴𝑣𝑎𝑖𝑏𝑖𝑙𝑖𝑡𝑦 =
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑡𝑖𝑚𝑒
=
𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒−𝑑𝑜𝑤𝑛 𝑡𝑖𝑚𝑒
𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒
Effort to improve the manufacturing industry can be ..........................(1)
seen in term of equipment by increasing the
effectivenesEffeectiveness is a measure that states how far Performance ratio describes the ability of equipment
the target (quantity, quality, and time) has been achieved, to produce goods. This ratio is the result of operating speed
the higher the effectiveness (Andras, 2007). High rate and net operating rate. The equipment operating speed
effectiveness values can be achieved if in the production rate refers to the difference between the ideal speed (based
process the company can reduce the value of losses, one of on the design of the equipment) and the actual operating
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ISSN No:-2456-2165
speed. Operating rate measures the maintenance of a speed RSL Reduced Speed Losses is a loss because the
during a certain period.In other words, it measures whether engine does not work optimally (decrease in speed of
an operation remains stable in a period as long as the operation) occurs the actual speed of machine operation or
equipment operates at a low speed. The formula for smaller equipment designed (Saiful, et al. 2014). To
measuring this ratio is: calculate the reduced speed losses used the formula:
𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 𝑟𝑎𝑡𝑒 = 𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑡𝑖𝑚𝑒−𝐼𝑑𝑒𝑎𝑙 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑡𝑖𝑚𝑒

RSL= 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒
𝑥100%
𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑒𝑑 𝑎𝑚𝑜𝑢𝑛𝑡 𝑥 𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒
𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑡𝑖𝑚𝑒
........(2)
Process Defect Losses are defective products that are
Quality ratio describes the ability of equipment to produced will result in material losses reducing the amount
produce products that comply with standards. The formula of production, production waste increasing and increasing
used to measure this ratio is: costs for rework (Limantoro& Felecia, 2013). To calculate
the defect losses process, the formula is used:
𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑒𝑑 𝑎𝑚𝑜𝑢𝑛𝑡−𝑑𝑒𝑓𝑒𝑐𝑡 𝑎𝑚𝑜𝑢𝑛𝑡
𝑄𝑢𝑎𝑙𝑖𝑡𝑦 𝑅𝑎𝑡𝑒 = 𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑒𝑑 𝑎𝑚𝑜𝑢𝑛𝑡
….(3)
Process defect losses =
𝐼𝑑𝑙𝑒 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 𝑋 𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 𝑑𝑒𝑓𝑒𝑐𝑡
OEE value is obtained by multiplying the three main 𝑥100%
𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒
ratios. Mathematically the formula for measuring OEE
values is as follows: Reduced Yield Losses are losses incurred during the
time needed by the machine to produce new products with
OEE (%) = Availability (%) x Performance Rate (%) x the expected product quality.Losses that arise depend on
Quality Rate (%)…(4) factors such as unstable operating conditions, improper
handling and installation of equipment or operators do not
 Six Big Losses understand the production activities carried out (Limo &
There are six disadvantages as cause low performance Felecia, 2013). For reduced yield losses the formula is
of machines and equipment, namely equipment failure used:
(breakdown losses), setup and adjustment losses, idling and
minor stoppage losses, reduced speed losses, process defect 𝑁𝑜𝑛𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑒 𝑡𝑖𝑚𝑒
Reduced yield losses = 𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒
𝑥100%
losses, reduced yield losses (Saiful, et al, 2014).
Breakdown losses are damage to the engine or equipment
that suddenly experiences unwanted damage and  Fishbone Diagram
consequently will cause the engine to not operate properly. Fishbone diagram is a method for analyzing the
To calculate the Breakdown Losses (BL) formula is used : causes of a problem or condition. This diagram is also
called the cause-effect diagram. The inventor was Professor
𝑇𝑜𝑡𝑎𝑙 𝑏𝑟𝑒𝑎𝑘𝑑𝑜𝑤𝑛 𝑡𝑖𝑚𝑒 Kaoru Ishikawa, a Japanese scientist who was also an
BL = 𝑥100.............(5) alumni of the chemical engineering University of Tokyo, in
1943. So it is also called the Ishikhawa diagram.Fishbone
Setup and Adjustment Losses (SAL) are losses due to diagram or cause and effect diagram can be used to:
installation and adjustment (Saiful, et al, 2014). to calculate
setup and adjustment losses the formula is used:  Identify the root causes of a problem
 Get ideas that can provide solutions for solving a
SAL =
𝑇𝑜𝑡𝑎𝑙 𝑠𝑒𝑡𝑢𝑝 𝑎𝑛𝑑 𝑎𝑑𝑗𝑢𝑠𝑡𝑚𝑒𝑛𝑡 𝑙𝑜𝑠𝑠𝑒𝑠
𝑥100%...(6) problem
𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒  Assist in search and further investigation of facts
Idle and Minor Stoppage Losses (IMSL) are caused III. RESULT AND CONCLUSION
by events such as short engine stops, engine congestion,
and idle time of the engine (Saiful, et al., 2014). To From the OEE calculation on the Die Casting
calculate the idle and minor stoppages losses, the formula is machine, researchers took a sample of 5 months for data
used: collection from July 2018 to November 2018. For Overall
Equipment Effectiveness the results of multiplication of the
𝑁𝑜𝑛𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑒 𝑡𝑖𝑚𝑒 three elements are availability, performance rate, and
IMSL = 𝑥100%......(7)
quality rate. Before getting the OEE value, the calculation
of these three elements is carried out every month, the
calculation results can be seen in the picture below:

ISSN No:-2456-2165
Fig 1:- Graph of OEE Element Comparation
From the fig, it can be seen that Performance has a the performance value has a smaller value than the two
relatively lower value with an average value of 69%, and elements, which of course will affect the OEE value on die
the quality rate value has a higher relative value with an casting machines tend to not match the values set by the
average value of 96%, and for the value of availability it world class.
has an average value of 96% . With this, it can be seen that
Fig 2:- OEE calculation Chart
From the graph above, it can be seen that the that the performance rate value that causes the overall
achievement of all OEE elements is still below the world equipment effectiveness value becomes nonstandard.
class. However, the most striking value in the calculation is
the value of performance that is still very far below the After the OEE calculation is done, then the next step
world class. Which results in an OEE average that is still is to calculate the proportion or percentage of each six big
far from world class standards. So that it can be concluded losess. Percentage of sig big losess can be seen in the
picture below:

ISSN No:-2456-2165
Fig 3:- Six Big Losess Calculation Chart
From the Pareto chart above, it is concluded that the using a graph of causality (fishbone) to find out more
loss due to Performance loss to the low OEE value. clearly the root of the problem.
Therefore this analysis will focus on reducing speed by
Fig 4:- FisboneDiagran Reduced Speed
In the Fig above shows that cause and effect of several Based on the analysis using the Pareto diagram for the
factors that can affect the height of reduced speed. It can be six big losses that affect the OEE value, is the performance
seen from the fishbone diagram that dominates the cause, loss, namely reduced speed losess with an average
namely, the lack of training in the carway in machine percentage value of 65%. From the results of the analysis it
operation and preventive maintenance has not been running can be concluded that the main cause that affects the low
continuously on the machine. Which causes the engine to OEE value is Reduced Speed Losess.In addition,
damage the engine often so that the engine cannot process researchers analyzed using fishbone diagrams to find out
properly. which factors were very influential by looking at several
factors, namely from Machine, Method, Material, and Man.
IV. CONCLUSION Of the four factors which have an effect on reduced speed
losess, preventive maintenance is not performed optimally
Based on research conducted in July 2018 to on the machine and the operator is less skilled in using the
November 2018, the company has not implemented Total machine, so that the machine often has trouble and inhibits
Productive Maintenance in its production process activities, production activities.
so researchers are interested in calculating OEE values and
getting an OEE value of 64%, this value is still far from
world class standards.

ISSN No:-2456-2165
SUGGESTIONS
After the researchers conducted data processing,

analysis and concluded the whole study, the following
researchers will give some suggestions that should be done
so that the problems that occur are not repeated:
 It is expected that the company can carry out preventive

continuously so that the engine can run optimaly.
 Make scheduling preventive maintenance processes for
each machine. In order to minimize the occurrence of
excessive breakdown
 Conduct training for employees so that employees can
use and understand the procedures for using the
machine properly and correctly, if the employee cannot
use or operate the machine properly, this will cause
damage to the machine and make the line stop
production process so that the engine performance
decreases.
REFERENCES
[1]. Suliantoro, H., Susanto, N., Prastawa, H., Sihombing,

I., &Mustikasari, A. (2017). PenerapanMetode
Overall Equipment Effectiveness (OEE) dan Fault
Tree Analysis (FTA)
untukMengukurEfektifitasMesinReng. J@ ti Undip:
JurnalTeknikIndustri, 12(2), 105-118.
[2]. Susetyo, A. E. (2017). Analisis Overall Equipment
Effectivenes (OEE)
untukMenentukanEfektifitasMesinSonna Web.
SCIENCE TECH:
JurnalIlmiahIlmuPengetahuandanTeknologi, 3(2), 93-
102.
[3]. Sashkiadewiali (2019). Fishbone diagram diakses 14
juni 2019
padahttps://sis.binus.ac.id/2017/05/15/fishbone-
diagram/
[4]. Limantoro, D. (2013). Total Productive Maintenance
di PT. X. JurnalTitra, 1(1), 13-20.
[5]. Saiful, S., Rapi, A., &Novawanda, O. (2014).
PENGUKURAN KINERJA MESIN DEFEKATOR I
DENGAN MENGGUNAKAN METODE OVERALL
EQUIPMENT EFFECTIVENESS (StudiKasuspada
PT. Perkebunan XY). Journal of Engineering and
Management in Industrial System, 2(2).
[6]. Nakajima, S. (1988). Introduction to TPM: total
productive maintenance.(Translation). Productivity
Press, Inc., 1988,, 129.

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Volume 4, Issue 7, July – 2019 International Journal of Innovative Science and Research Technology

Calculation of Overall Equipment Effectiveness Total

I. INTRODUCTION II. RESEARCH METHOD

In manufacturing or non-manufacturing industry, This research consists of several stages of data

IJISRT19JL255 www.ijisrt.com 442

𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 𝑟𝑎𝑡𝑒 = 𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑡𝑖𝑚𝑒−𝐼𝑑𝑒𝑎𝑙 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑡𝑖𝑚𝑒

IJISRT19JL255 www.ijisrt.com 443

Fig 1:- Graph of OEE Element Comparation

Fig 2:- OEE calculation Chart

IJISRT19JL255 www.ijisrt.com 444

Fig 3:- Six Big Losess Calculation Chart

Fig 4:- FisboneDiagran Reduced Speed

IJISRT19JL255 www.ijisrt.com 445

After the researchers conducted data processing,

 It is expected that the company can carry out preventive

[1]. Suliantoro, H., Susanto, N., Prastawa, H., Sihombing,

IJISRT19JL255 www.ijisrt.com 446

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