Total Productive Maintenance Analysis on Printing Machine (A Case Study in an Indonesian Flexible Packaging Manufacturer)

ABSTRACT: PT XYZ is one of Indonesia’s major flexible packaging manufacturer companies. The company suffers losses from the increase in printing machine breakdown from 1.65% in 2019 to 2.52% in 2021. This paper aims to reduce the breakdown duration in 2022 by identifying and solving the root cause by implementing one of the alternative solutions. The primary data are collected via a series of interviews and from the company’s manufacturing reports. Using Current Reality Tree (CRT) the root cause was identified as a lack of regular maintenance evaluation and improvement. The study proposes three alternative solutions: Planned Maintenance (PM), Autonomous Maintenance (AM), and condition-based maintenance using IoT sensors. In determining the preferred alternative, the study uses Analytic Hierarchy Process (AHP) with five criteria: OEE improvement, human capital improvement, Capex required, Opex required, and ease of implementation. Align with the AHP result, the company agreed to implement Planned Maintenance (PM). After the first two months of implementation, the average year-to-date breakdown in 2022 was reduced to 2.29%.