DEVELOPING MAINTENANCE PROCEDURE TO REDUCE BREAKDOWN IN CAPPING AND CARTONING MACHINE AT PT. XYZ MANUFACTURING INDONESIA By Muhammad Faizin Rissa NIM: 004201100011 A Thesis presented to the Faculty of Engineering President University in partial fulfillment of the requirements of Bachelor Degree in Engineering Major in Industrial Engineering 2015 THESIS ADVISOR RECOMMENDATION LETTER This thesis entitled “Developing Maintenance Procedure to Reduce Breakdown in Capping and Cartoning Machine at PT.XYZ Manufacturing Indonesia” prepared and submitted by Muhammad Faizin Rissa in partial fulfillment of the requirements for the degree of Bachelor Degree in the Faculty of Engineering has been reviewed and found to have satisfied the requirements for a thesis fit to be examined. I therefore recommend this thesis for Oral Defense. Cikarang, Indonesia, 25 March, 2015 Ir. Hery Hamdi Azwir, MT i DECLARATION OF ORIGINALITY I declare that this thesis, entitle “Developing Maintenance Procedure to Reduce Breakdown in Capping and Cartoning Machine at PT.XYZ Manufacturing Indonesia” is, to the best of my knowledge and belief, an original piece of work that has not been submitted, either in whole or in part, to another university to obtain a degree. Cikarang, Indonesia, 25 March, 2015 Muhammad Faizin Rissa ii DEVELOPING MAINTENANCE PROCEDURE TO REDUCE BREAKDOWN IN CAPPING AND CARTONING MACHINE AT PT. XYZ MANUFACTURING INDONESIA By Muhammad Faizin Rissa NIM. 004201100011 Approved by Ir. Hery Hamdi Azwir, MT Ineu Widaningsih, ST., MT Thesis Advisor 1 Thesis Advisor 2 Herwan Yusmira, B.Sc. MET, MTech Program Head of Industrial Engineering iii ABSTRACT PT. XYZ Manufacturing Indonesia is a factory engaged in the manufacture of cosmetics. PT. XYZ Manufacturing Indonesia is the biggest manufacture XYZ in the world. With the huge number of production line, meaning that the factory will face lots of problem in machine performance. Due to limitation of time, this research is focus on production line Jar J5. In the last four month, the production efficiency or OEE in line Jar J5 cannot archive the target. The production efficiency target for line Jar J5 is 60%, but based on historical data in the last four month the line efficiency only reaches 56.3%. The decreasing of efficiency happened because of the losses that coming from breakdown, changeover, and waiting during production time. Pareto analysis is perform to see the biggest line stop coming from each losses. Based on Pareto analysis it show that breakdown time make the efficiency decreased more than 60% and machine that produce the highest breakdown are capping and cartoning machine. FMEA is apply for finding the area that make the machine breakdown. After knowing the core problem, 5 whys analysis is used to find the root cause. Based on 5 whys analysis, maintenance procedure are needed to obtain the optimum production. Maintenance procedure are applied in caping and cartoning machine. During seven week of implementation maintenance procedure, breakdown time in capping and cartoning machine decreased from 466 minutes to 138 minutes, the overall equipment efficiency also improved from 50% to 65%. Keywords: Overall Equipment Efficiency (OEE), Production Time, Pareto Analysis, Failure Mode and Effect Analysis (FMEA), Five Whys Analysis, Maintenance Procedure. iv ACKNOWLEDGEMENT Gratefully, I can punctually finish this final project. I would like to express my greatest appreciation for those who always supported me and provided assistance in completing this final project. With all due respects, I offer my special thanks to: 1. Allah SWT. The Almighty God and The Most Merciful. Your blessing and gift of health gives me power to finish this final project. 2. My father, Ridwan Sufi. Thank you for the support, knowledge, and countless great advices. 3. My mother, Saritawati. My spirit comes from your sincerity of love and endless prayers. 4. Mr. Arthur Henry, as my manager during my internship program. Thank you for the opportunities that you give to me. 5. Mrs. Eriyana Swanthy, as my supervisor during my internship program. Thank you for the knowledge and opportunity to handle lots of project. I learn so many things from you. 6. Mrs. Agnes Pascalia. Thank you for the guidance and opportunity for me in elaborating this topic for my final project. 7. All Quality department team, Mr. Daryana, Mr. Chakim, Mr. Rachmat, Mr.Alvi, Mrs. Esti, Mrs. Yuni, and Mrs. Nur Rochmah, Thank for your support and prayers. 8. All the FMC (Factory Magang Committee), Angga Mahatma, Ardisa Pramudita, Icha M.sholihah, Kristiantho Sulistiohadi, Luqman Nurhakim, Tia Darlia, and Yusrina Husna. Thank you for your time and support. 9. Mr. Hery and Mrs. Ineu as my thesis advisor. This project cannot be completed without the practice given to me and also your advices and support. v 10. Mrs. Andira. Thank you for answering every question I asked and for every little sharing time. I am waiting for an opportunity to have another sharing time, but not about academic things. 11. My best friends, Ainul Frisky, Adhi Hananto, Ivena Damara, Teuku Mirwan, Narfrida Rara, and Riski Borman, Your laugh, prayers, and support made me powerful to finish all of this. 12. All my classmate in Industrial Engineering 2011, thank you for this 3 years being together. vi TABLE OF CONTENTS THESIS ADVISOR ................................................................................................. i RECOMMENDATION LETTER ........................................................................... i DECLARATION OF ORIGINALITY ................................................................... ii APPROVAL PAGE ............................................................................................... iii ABSTRACT ........................................................................................................... iv ACKNOWLEDGEMENT ...................................................................................... v TABLE OF CONTENTS ...................................................................................... vii LIST OF TABLES .................................................................................................. x LIST OF FIGURES ............................................................................................... xi LIST OF APPENDIX .......................................................................................... xiii LIST OF TERMINOLOGY ................................................................................. xiv CHAPTER I INTRODUCTION ............................................................................. 1 1.1 Problem Background ..................................................................................... 1 1.2 Problem Statement ........................................................................................ 2 1.3 Objective ....................................................................................................... 2 1.4 Scope and Limitation .................................................................................... 2 1.5 Assumption ................................................................................................... 3 1.6 Research Outline ........................................................................................... 3 CHAPTER II STUDY LITERATURE ................................................................... 5 2.1 Failure Mode and Effect Analysis ................................................................ 5 2.5.1 Application of the Design FMEA .......................................................... 6 2.2 Lean thinking ................................................................................................ 9 2.3 Comparing lean manufacturing and FMEA ................................................ 11 vii 2.4 Pareto Analysis ........................................................................................... 13 2.4.1 Pareto Graph......................................................................................... 14 2.5 Production Time .......................................................................................... 14 2.2.1 Planned down time ............................................................................... 15 2.2.2 Occupation time ................................................................................... 17 2.2.2.1 Waiting Time ................................................................................ 17 2.2.2.2 Breakdown Time ........................................................................... 18 2.2.2.3 Changeover Time (reference changes).......................................... 18 2.2.2.4 Non-qualified Time ....................................................................... 19 2.2.2.5 Operating Time ............................................................................. 19 2.6 Overall Equipment Efficiency (OEE) ......................................................... 20 2.6.1 OEE Benchmarks ................................................................................. 20 2.6.2 Calculating OEE................................................................................... 21 2.6.2.1 Nominal Speed .............................................................................. 23 2.6.2.2 Micro-Stoppages ........................................................................... 24 2.6.2 OEE Time Collection ........................................................................... 24 2.7 Five Whys analysis ....................................................................................