ANALISIS OVERALL EQUIPMENT EFFECTIVENESS DAN USULAN PERBAIKAN BERBASIS TOTAL PRODUCTIVE MAINTENANCE PADA MESIN LABELLING RL500 DI PT BIO FARMA (PERSERO)

Abstrak

PT Bio Farma (Persero) sebagai satu-satunya produsen vaksin milik negara dituntut menjaga produktivitas dan mutu produksi secara simultan. Mesin Labelling RL500 pada Packaging Line 1 Gedung 43 berkedudukan sebagai bottleneck lini pengemasan, namun tingkat efektivitasnya rendah sehingga menghambat pemenuhan target produksi. Penelitian ini bertujuan mengidentifikasi jenis kerugian yang paling dominan menyebabkan rendahnya nilai Overall Equipment Effectiveness (OEE), menganalisis akar penyebab utamanya, serta menyusun usulan perbaikan dengan pendekatan Total Productive Maintenance (TPM) yang mengacu pada pilar Autonomous Maintenance dan Planned Maintenance. Penelitian menggunakan pendekatan kualitatif deskriptif-analitik dengan rancangan studi kasus tunggal terpancang. Data sekunder berupa Summary Report periode Januari–Juni 2026 yang mencakup 18 batch produksi, dan data primer melalui observasi lapangan serta wawancara mendalam dengan tujuh informan. Analisis mengintegrasikan empat alat secara berurutan, yaitu Six Big Losses, Diagram Pareto, Fishbone Diagram (5M1E), dan Failure Mode and Effect Analysis (FMEA). Hasil penelitian menunjukkan nilai OEE rata-rata 50,85%, jauh di bawah standar world class JIPM 85%, dengan Performance Rate (54,00%) sebagai komponen terkritis, sementara Availability (95,22%) dan Quality (98,94%) tergolong baik. Kerugian dominan adalah Idling and Minor Stoppage (61,08%) dan Reduced Speed (28,17%) dengan kontribusi kumulatif 89,25%. Penelusuran akar penyebab menghasilkan enam belas akar penyebab pada kerangka 5M1E dan empat belas modus kegagalan, dengan Risk Priority Number tertinggi pada penghentian singkat yang tidak teranalisis (320) dan keausan komponen yang tidak terdeteksi dini (294). Keluaran penelitian berupa dua belas usulan perbaikan terprioritas yang setiap butirnya dapat dirunut balik hingga modus kegagalan, akar penyebab, kerugian dominan, dan nilai OEE awal.

PT Bio Farma (Persero), as Indonesia’s sole state-owned vaccine manufacturer, must sustain production productivity and quality simultaneously. The RL500 labelling machine on Packaging Line 1 serves as the bottleneck of the packaging line, yet its low effectiveness constrains the fulfilment of production targets. This study aims to identify the most dominant losses causing the low Overall Equipment Effectiveness (OEE), to analyse their main root causes, and to formulate improvement proposals based on the Autonomous Maintenance and Planned Maintenance pillars of Total Productive Maintenance (TPM). The study employs a qualitative descriptive-analytic approach with an embedded single-case study design. Secondary data comprised the Summary Report for January–June 2026 covering 18 production batches, while primary data came from field observation and in-depth interviews with seven informants. The analysis sequentially integrates Six Big Losses, Pareto Diagram, Fishbone Diagram (5M1E), and Failure Mode and Effect Analysis (FMEA). The results show an average OEE of 50.85%, far below the JIPM world-class standard of 85%, with Performance Rate (54.00%) as the most critical component, whereas Availability (95.22%) and Quality (98.94%) are good. The dominant losses are Idling and Minor Stoppage (61.08%) and Reduced Speed (28.17%), with a cumulative contribution of 89.25%. Root-cause analysis yielded sixteen root causes across the 5M1E framework and fourteen failure modes, with the highest Risk Priority Numbers on unanalysed minor stoppages (320) and undetected early component wear (294). The study delivers twelve prioritised improvement proposals, each traceable back to its failure mode, root cause, dominant loss category, and baseline OEE value.