The main problem often faced by the
manufacturing industry is the high level of loses time,
which is illustrated by the low utilization rate of Total
Productive Maintenance (TPM) time and the impact on
the low level of effectiveness of the plant or equipment.
This is often caused by breakdown losses, setup and
adjustment losses, start-up losses, minor stoppage, idling,
speed losses, and defect losses. This study aims to
determine the time utilization of TPM and provide
suggestions for improvements to improve Overall
Equipment Effectiveness (OEE) time utilization and lead
to savings in production costs. Case studies were carried
out on manufacturing companies engaged in sport's
shoes and are the largest supplier of world sports shoe
brands. Products produced from this industry are the
Upper (upper part of the shoe), Outsole (the bottom of
the shoe), and Insole (the inside of the shoe) with the
main raw materials being leather, foam, and rubber.
From the results of data processing, it is obtained the
effectiveness value of the manufacturing process, which
is OEE, an average of 76.98% per month with a
component availability of 94.87%, a performance rate of
41.42%, and a quality rate of 94.74%. The main causes
of lost time are defect losses time of 4.74% per month of
total productive time and breakdown losses of 2.17% per
month of total productive time. Control process
measurements are carried out to determine variations in
the number of rework products and defects are still in
the control limits of statistical control. To make
improvements from the actual state, a new standard for
product quality is set, from the number of 53 pairs of
reworks and B'Grade (defective products sold at half the
price of good products) 2 pairs to 47 pairs and 1 pair
B’Grade. With the new work program and continuous
improvement, it is the factory can reduce the number of
rework products and B'Grade defects that can save up to
IDR 56,586,860 per month.
Keywords : Total Productive Maintenance, Overall Equipment Effectiveness, Statistical Process Control, Shoe’s Manufacturing Industry.
