Turkish Journal of Computer and Mathematics Education Vol.12 No.

7 (2021), 2768-2775
Research Article
The Calculation Analysis of Total Productive Maintenance (TPM) on the Plumatex
FFS894 Machine Using the Overall Equipment Effectiveness (OEE) Method at PT.XYZ
Pharmaceutical Company
1
Muhamad Anwar Septiana*, 2Moch. Fadhli Fathoroni Hermana, 3Rifki Hidayattulloh, 4Fajar
5
Permana and 6Didit Damur Rochman

Widyatama University, Bandung, Indonesia

*anwar.septiana@widyatama.ac.id

Article History: Received: 11 January 2021; Revised: 12 February 2021; Accepted: 27 March 2021; Published
online: 16 April 2021

Abstract: PT.XYZ is a company engaged in the pharmaceutical sector which is inseparable from problems
related to the effectiveness of machines or equipment causes by the effect of Six Big Losses. Therefore, we need
effective and efficient steps in the maintenance of machines or equipment to overcome and prevent these
problems. Total Productive Maintenance (TPM) is a management principle to increase the productivity and
efficiency of the Company's production by using machines effectively. Incorrect handling and maintenance of
machines will result in losses which are called Six Big Losses. The first step in the effort to increase production
efficiency at PT. XYZ Company is to measure the effectiveness of the Plumatex FFS894 machine using the
Overall Equipment Effectiveness (OEE) method which then measures Six Big Losses to find out the amount of
efficiency lost in the Six Big Losses factor. With a cause and effect diagram can analyze the actual problem
which is the main cause of the high losses resulting in the low effectiveness of the Plumatex FFS894 machine.
The conclusion on the Plumatex FFS894 machine is that the OEE value for the period of August 2020 to
January 2021 range from 77.76% to 86.82%, with an average OEE value of 82.73%. So, the Plumatex FFS894
machine has not reached the ideal conditions (≥85%). The factor that made the biggest contribution which result
in the low effectiveness of using the Plumatex FFS894 machine which is the main priority for improvement is
Reduced Speed Losses with a percentage of 25.76% and Idling and Minor Stoppage Losses with a percentage of
21.09%.
Keywords: Total Productive Maintenance (TPM), Overall Equipment Effectiveness (OEE)

INTRODUCTION
PT. XYZ is a pharmaceutical company which production is divided into two departments, namely Small
Volume Parenteral (SVP) and Large Volume Parenteral (LVP). Data retrieval for this paper will be carried out
at the LVP Production department. The product produced by the LVP department is an infusion which the
production process is carried out on the Flip-Off (FO) infusion type. In this process, it is expected that there will
be no reject infusions because the input from the machine is an infusion of good quality that has passed the
particle and fiber free inspection, as well as passed the leak test. However, in reality, reject infusion products are
still frequently produced in the production process. For this reason, an improvement is needed in order to
increase the effectiveness and efficiency of the Plumatex FFS894 machine, so that what is expected by the
company, namely the there is no reject in the infusion production process can be realized.
This paper aims to find out the value of Overall Equipment Effectiveness (OEE) on the Plumatex FFS894
machine at PT. XYZ. The next aim is to find out the value of Six Big Losses which affects the performance of
the Plumatex FFS894 machine. Furthermore, after finding out the value of Overall Equipment Effectiveness
(OEE) and the value of Six Big Losses, it will provide recommendations for improvements to overcome the
problem of the Six Big Losses factor at PT. XYZ the Pharmaceutical Company. The existence of competitive
price requires the pharmaceutical industry to run factory operations as efficiently as possible in order to produce
drugs at the lowest possible cost and still maintain the quality (Mubarok, 2019).
To maintain the condition of the Plumatex FFS894 machine so that it does not suffer damage or reduce the type
of damage time, and so that the production process does not stop too long, then a good machine care and
maintenance system is needed. If there is no machine care and maintenance system in the company, it will cause
losses to the company, which can directly reduce the effectiveness of the machine or equipment, and result in
costs that must be incurred due to damage to machines or equipment that can also affect the level of consumer
confidence. The losses experiences by this company are better known as Six Big Losses (Nakajima, 1988).
Implement the TPM method allows companies to find waste that arises and occurs in the production process,
then the TPM method also allows companies to find and eliminate the main factors that hinder the production
process. The calculation of Overall Equipment Effectiveness (OEE) on this production machine can be used as
the basis for the implementation of this Total Productive Maintenance method, where then the calculation of the

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The Calculation Analysis of Total Productive Maintenance (TPM) on the Plumatex FFS894 Machine
Using the Overall Equipment Effectiveness (OEE) Method at PT.XYZ Pharmaceutical Company

Six Big Losses factor value and the elimination of the biggest factor value of Six Big Losses is the final stage of
the Total Productive Maintenance method is used. (Stephens, Matthew, 2004).

LITERATURE REVIEW
A. Total Productive Maintenance (TPM)
Based on the Japanese Institute of Plant Maintenance (JIPM), the definition of TPM is a team-based
maintenance strategy to maximize equipment effectiveness by implementing a productive maintenance system
as a whole covering all equipment used, extending the life of the equipment associated with, usage, maintenance
and planning and involvement of all employees, from top management executives to production operators
(Sharma et al., 2006).
According to Borris, the definition of TPM is a simple and good engineering practice. TPM demands a root-
cause analysis solution. In both the equipment field service environment and the hospital environment, both
require ensuring failure events do not happen again. As well as the expected results are an impact on customers
and benefits for the Company (Borris, 2006;4).

B. Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness (OEE) is useful so that the condition of the equipment or machine is always in
an ideal state by eliminating 6 Big Losses on the equipment or machine. Based on Denso (2006) in the journal
(Sunaryo & Eko, 2015) states that 6 Big Losses are the cause of production equipment not operating normally.
Using OEE analysis will obtain a level of reliability from production equipment.
Based on Nakajima (1998) in the journal (Sunaryo & Eko, 2015) states that the Overall Equipment
Effectiveness (OEE) value can be said to meet the JIPM standard if, the Availability ratio value of 90%, the
Performance ratio value of 95%, the Quality ratio value of 99% and the Overall Equipment Effectiveness (OEE)
value of 85%. The Overall Equipment Effectiveness (OEE) value is obtained from multiplying three parameters,
namely as follows:

𝑂𝐸𝐸 (%) = 𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑅𝑎𝑡𝑒 × 𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 𝑅𝑎𝑡𝑒 × 𝑄𝑢𝑎𝑙𝑖𝑡𝑦 𝑅𝑎𝑡𝑒

1. Availability Ratio is a ratio that describes the benefits of operating time for available equipment or
machines with the following formula:

𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑅𝑎𝑡𝑖𝑜 = × 100%
𝐿𝑜𝑎𝑑𝑖𝑛𝑔 𝑇𝑖𝑚𝑒

2. Performance Efficiency is a ratio that describes the ability of the equipment or machine to produce goods
with the following formula:

𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑒𝑑 𝐴𝑚𝑜𝑢𝑛𝑡 × 𝐼𝑑𝑒𝑎𝑙 𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒

𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = × 100%
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒

3. Quality Rate is a ratio that describes the ability of an equipment or machine to produce products according
to standards with the following formula:

(𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑒𝑑 𝐴𝑚𝑜𝑢𝑛𝑡 − 𝐷𝑒𝑓𝑒𝑐𝑡 𝐴𝑚𝑜𝑢𝑛𝑡)

𝑄𝑢𝑎𝑙𝑖𝑡𝑦 𝑅𝑎𝑡𝑒 = × 100%
𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑒𝑑 𝐴𝑚𝑜𝑢𝑛𝑡

C. Six Big Losses

According to Chen et al. (2005) in the journal (Erna & Hafid, 2017) The decrease in the level of performance of
a machine or equipment which results in the machine or equipment not operating ideally, efficiently and
effectively, namely as follows:
1. Breakdown Losses namely wasted idle time resulting in a reduction in the amount of production.
2. Set-up and adjustment losses (make-ready) namely the losses resulting from the set-up time and
adjustment is the entire set-up time including the setting time.
3. Idling and Minor Stoppage namely a loss due to minor disturbances and idle time due to external factors so
that the machine stops production.
4. Reduced Speed Losses namely the losses when the speed of the equipment or machine decreases so that it
does not operate optimally.

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Muhamad Anwar Septiana*, 2Moch. Fadhli Fathoroni Hermana, 3Rifki Hidayattulloh, 4Fajar
5
Permana and 6Didit Damur Rochman

5. Defect and Rework Losses namely a product that does not comply with the specified quality
specifications, even though the product can still be reworked.
6. Yield or scrap losses namely losses appear at the beginning of the production time that has not been able to
achieve stable production conditions.
METHOD
METHOD
Collecting Data Processing Data
1. Measuring the level of effectiveness
1. Primary Data and efficiency with the OEE method
a. Production process 2. Calculate Six Big Losses
b. Organization structure
c. Working Hours
2. Observation Result and Discussion
a. Production data 1. OEE analysis
b. Downtime data 2. Six Big Losses analysis
c. Product reject data 3. Pareto Diagram analysis
4. Fishbone Diagram analysis
5. Proposing Problem Solving

Figure 1. Research Methodology Diagram

1. Collecting Data
Collecting primary and secondary data is by observing, observing and recording at PT. XYZ. The aim of this
observation is that researchers to obtain valid data for materials to compile paper. Researchers uses the data in
this paper, including:
a. Infusion production result data in August 2020 – January 2021;
b. Plumatex FFS894 machine downtime data in August 2020 – January 2021;
c. Reject data for infusion production in August 2020 – January 2021.

2. Processing Data
Processing data uses the Overall Equipment Effectiveness method, with the assistance of the Microsoft Excel
2010 software application
a. Calculating the Availability Value
b. Calculating the Performance Efficiency Value
c. Calculating the Rate of Quality Product Value
d. Calculating the Overall Equipment Effectiveness (OEE) Value
e. Calculating the OEE Six Big Losses Value

3. Results and Discussion

Carry out analysis to find out the results of the continuation of the data processing stage. At this stage the
researchers analyze all the results of calculations, namely the value of Availability, Performance Efficiency,
Rate of Product Quality, Overall Equipment Effectiveness, and OEE Six Big Losses which then determines the
dominant problem using the Pareto diagram. In addition, the researchers carry out an analysis to obtain the root
of the problem that occurs by using a cause and effect diagram in order to determine the proposed
troubleshooting.

RESULTS AND DISCUSSION

A. OEE Value
Data for data processing that can measure the effectiveness of the object of this paper is the Plumatex FFS894
machine because it has a quite high level of damage. Measurement of effectiveness uses the Overall Equipment
Effectiveness (OEE) method from reports on production and maintenance activities at the production unit at PT.
XYZ. Plumatex FFS894 machine data for the period of August 2020 to January 2021 are the data use in this
paper.
All data information uses historical data from the Company, interviews and brainstorming. Furthermore, the
data processing is processed. The initial stage, it is necessary to carry out three measurement ratios, namely
Availability, Performance Efficiency Ratio, Rate of Quality on the Plumatex FFS894 machine with data
processing using Microsoft Excel 2010 software. The results of OEE calculations on the Plumatex FFS894
machine are as follows.

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The Calculation Analysis of Total Productive Maintenance (TPM) on the Plumatex FFS894 Machine
Using the Overall Equipment Effectiveness (OEE) Method at PT.XYZ Pharmaceutical Company

Table 1. Availability Plumatex FFS894

Loading time Downtime Operating time Availability Availability
Period
(hours) (hours) (hours) (%) Standard (%)
August-20 405 43 362 89.38 90
September-20 504 46 458 90.87 90
October-20 455 53 402 88.35 90
November-20 475 49 426 89.68 90
December-20 433 54 379 87.53 90
January-21 455 59 396 87.03 90

Table 2. Performance Efficiency Ratio Plumatex FFS894

Total Good Ideal Cycle Operating Performance Performance Efficiency
Period
Products (pcs) Time (hours) Time (hours) Efficiency % Standard (%)
August-20 10194 0.035 362 97.68 95
September-20 10201 0.044 458 98.00 95
October-20 10442 0.037 402 96.88 95
November-20 10450 0.040 426 97.76 95
December-20 10534 0.034 379 94.78 95
January-21 10573 0.036 396 96.29 95

Table 3. Rate of Quality Plumatex FFS894

Total Good Total Reject Rate of Quality Rate of Quality Product
Period
Products (pcs) Product (pcs) Product (%) Standard (%)
August-20 10194 320 96.86 99.9
September-20 10201 256 97.49 99.9
October-20 10442 410 96.07 99.9
November-20 10450 310 97.03 99.9
December-20 10534 660 93.73 99.9
January-21 10573 493 95.34 99.9

Table 4. OEE Plumatex FFS894

Avialibility Performance Rate of Quality OEE Ideal
Period OEE (%)
(%) Efficiency (%) Product (%) (%)
August-20 89.38 97.68 96.86 84.57 85
September-20 90.87 98.00 97.49 86.82 85
October-20 88.35 96.88 96.07 82.24 85
November-20 89.68 97.76 97.03 85.08 85
December-20 87.53 94.78 93.73 77.76 85
January-21 87.03 96.29 95.34 79.89 85
Average 88.81 96.90 96.09 82.73 85

Figure 2. Comparison Graph of OEE Factor Plumatex FF894

Based on the graph of OEE data processing results on the Plumatex FFS894 machine, the Availability of
88.81% is still below the JIPM standard, which is 90%, the Performance Efficiency of 96.90% is above the
JIPM standard, which is 95%, the Rate of Quality of 96.09% is still below the JIPM standard, which is 99.9%
and Overall OEE of 82.73% is still below the JIPM standard, which is 85%. Overall, the Plumatex FF894
machine is not operating effectively according to the JIPM standard, but still can make improvements to achieve
the ideal value. The results are quite good on the Performance Efficiency ratio because the value of the analysis
results show that it had a value above the JIPM standard.

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Muhamad Anwar Septiana*, 2Moch. Fadhli Fathoroni Hermana, 3Rifki Hidayattulloh, 4Fajar
5
Permana and 6Didit Damur Rochman

B. Six Big Losses

The OEE value on Plumatex FFS894 has obtained results, then the next step is to process data on each of the Six
Big Losses factors to find out the biggest factor that affects OEE. In order to see more clearly the effect of Six
Big Losses on the effectiveness of the Plumatex FFS894 machine, the calculation of Time Losses, the
Cumulative percentage of Six Big Losses, and the Pareto Diagram is as follows.

Table 5. Cumulative Percentage on Plumatex FFS894 Machine

Total Time Percentage Cumulative
No Six Big Losses
Losses (hours) (%) Percentage (%)
1 Reduced Speed Losses 136.85 25.76 25.76
2 Idling & Minor Stoppage Losses 112.00 21.09 46.85
3 Setup and Adjusment Losses 97.00 18.26 65.11
4 Breakdown Losses 95.00 17.89 83.00
5 Deffect Losses 90.30 17.00 100.00
6 Yield or Scrap Losses 0.00 0.00 100.00
Total 531.14

Figure 3. Pareto Diagram of Six Big Losses on Plumatex FFS894 Machine

Based on the analysis of the Six Big Losses factor, it will obtain the factors that become the top priority to make
improvements in increasing effectiveness. By making a Pareto diagram of each factor in Six Big Losses to Total
Time Losses based on Table 5 and Figure 2, the factors that contribute most to the low effectiveness of the
Plumatex FFS894 machine are Reduced Speed Losses of 136.85 hours of time losses and a Percentage of
25.76% as well as Idling & Minor Stoppage Losses of 112 hours of time losses and a Percentage of 21.09%
which causes the time to be ineffective.

C. Fishbone
After calculating the six big losses, resulting graph looks like the six big losses. The factors that most influence
the value of machine effectiveness are the Reduce speed and idling minor and stoppage factors, then carry out a
cause and effect analysis of these two factors using a fishbone diagram as shown below.

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The Calculation Analysis of Total Productive Maintenance (TPM) on the Plumatex FFS894 Machine
Using the Overall Equipment Effectiveness (OEE) Method at PT.XYZ Pharmaceutical Company

Figure 4. Fishbone Diagram of Reduce Speed Loss Global

Figure 5. Fishbone Diagram of Idling Minor and Stoppage Losses Global

These results are still too widespread after reducing the cause and effect of the problem as shown below.

Figure 6. Fishbone Diagram of Special Reduce Speed Loss

2773
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Muhamad Anwar Septiana*, 2Moch. Fadhli Fathoroni Hermana, 3Rifki Hidayattulloh, 4Fajar
5
Permana and 6Didit Damur Rochman

Figure 7. Fishbone Diagram of Special Idling Minor and Stoppage Losses

After finding out the cause of the problem from the reduce speed loss and idling minor stoppage factors using a
fishbone diagram, carry out a proposed troubleshooting for each of the causes to increase machine productivity.

Table 6. Proposed Troubleshooting Most Affect Reduce Speed Losses

No Factor Problem Problem Solving
Do periodic checks, Perform replacement parts
Many parts are worn out,
1 Machine when it looks abnormal, Perform lubrication for
Lack of maintenance.
dynamic parts.
Perform regular cleaning either after the process
2 Environment Rarely Cleaning.
is complete or shift changes.

Table 7. Proposed Troubleshooting Most Affect Idling Minor Stoppage Losses

No Factor Problem Problem Solving
1 Machine Incorrect machine settings Train technicians, Provide work instruction manual.
Do a daily check, Find out about the engine part life
Lack of checking engine condition,
2 Method time, Make a preventive maintenance schedule according
There is no standard part replacement.
to the prevailing circumstances.

CONCLUSION
This paper aims to find out the Overall Equipment Effectiveness (OEE) value and find out the Six Big Losses
value on the Plumatex FFS894 machine at PT. XYZ Pharmaceutical Company and determine recommendations
for improvement in overcoming the problem of the Six Big Losses factors at PT. XYZ Pharmaceutical
Company. The results of data processing in this paper show that the Availability value of 88.81% is still below
the standard due to the large number of inappropriate installation activities that affect the readiness of the
machine, while the Performance Efficiency value of 96.90% is above the applicable standard due to the
reliability of technicians in troubleshooting, and The Rate of Quality value of 96.09% is still classified below the
standard value, influences by incorrect initial installation, so that the Overall Equipment Effectiveness value of
82.73%, this value is still below the standard. The OEE value is quite good but still not optimal, so that in order
to achieve the optimal value, we can make improvements to the machine maintenance strategy either
periodically or based on life time part in order to increase the value of availability and Rate of Quality. The
biggest factor causing the low effectiveness of the Plumatex FFS894 machine is Reduced Speed Losses of
136.85 hours of time losses and a Percentage of 25.76% as well as Idling & Minor Stoppage Losses of 112
hours of time losses and a Percentage of 21.09% which causes ineffective time. Furthermore, after finding out
the results of data processing in this paper, PT. XYZ can carry out OEE calculations on all machines used in
production aiming to obtain representative data and information to determine component prevention and
periodic inspections in accordance with predetermined usage time interval calculations in order to reduce
machine downtime during production.

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The Calculation Analysis of Total Productive Maintenance (TPM) on the Plumatex FFS894 Machine
Using the Overall Equipment Effectiveness (OEE) Method at PT.XYZ Pharmaceutical Company

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