Analysis of Cut Size Paper Cutting Machine Performance Using Total Productive Maintenance Concept (Case Study: PT. RST)
Abstract
PT. RST, a leading paper factory in Indonesia, prioritizes timely production by optimizing productivity, efficiency, and paper quality. This study assesses the reliability of the Cut Size (CS) paper cutting machine, which is enhanced through the implementation of Total Productive Maintenance (TPM) as a management philosophy to ensure high-efficiency operations. To evaluate machine performance, Overall Equipment Effectiveness (OEE) measurement is used. From data collected from January to September 2023, an analysis is conducted to improve the performance of the CS machine, which has not met its set target. The average OEE value of 70.9% falls short of the target of 72%. This research aims to improve the performance of the CS machine through the TPM approach, focusing on the Focused Maintenance pillar. Using tools such as Pareto diagram, why-why analysis, fishbone diagram, and the 5W1H method, several sources of problems causing the decrease in OEE value will be identified and addressed.
##Keywords:##
Total Productive Maintenance (TPM), Cut Size (CS), Overall Equipment Effectiveness (OEE), Pareto, Why-why analysis, Fishbone
Published
Jul 30, 2024
How to Cite
MUSTAFA, Rolandi; SUSILAWATI, Anita; MULYADI, Ismet Hari.
Analysis of Cut Size Paper Cutting Machine Performance Using Total Productive Maintenance Concept (Case Study: PT. RST).
Journal of Ocean, Mechanical and Aerospace -science and engineering-, [S.l.], v. 68, n. 2, p. 64-74, july 2024.
ISSN 2527-6085.
Available at: <https://isomase.org/Journals/index.php/jomase/article/view/365>. Date accessed: 18 apr. 2026.
doi: http://dx.doi.org/10.36842/jomase.v68i2.365.
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[2] A. Tomlinson, “Introduction to the TPM,” Smart Cards, Tokens, Security and Applications, pp. 173–191, 2017.
[3] M. Ardi, A. Sutanto, and A. Susilawati, “Analysis of Effectiveness of Cut Size Line Machines Based on Total Productive Maintenance (TPM) and Analytical Hierarchy Process (AHP)-A Case Study,” Journal of Ocean, Mechanical and Aerospace-science and engineering-, vol. 67, no. 3, pp. 109–117, 2023.
[4] A. K. Gupta and R. K. Garg, “OEE improvement by TPM implementation: a case study,” International Journal of IT, Engineering and Applied Sciences Research, vol. 1, no. 1, pp. 115–124, 2012.
[5] S. Singh, J. S. Khamba, and D. Singh, “Analyzing the role of six big losses in OEE to enhance the performance: literature review and directions,” Advances in Industrial and Production Engineering: Select Proceedings of FLAME 2020, pp. 411–421, 2021.
[6] D. H. Stamatis, The OEE primer: understanding overall equipment effectiveness, reliability, and maintainability. CRC Press, 2017.
[7] I. P. S. Ahuja and J. S. Khamba, “Total productive maintenance: literature review and directions,” International journal of quality & reliability management, 2008.
[8] B. Steven, “Total Productive Maintenance: Proven strategies and techniques to keep Equipment running at peak efficiency,” DOI, vol. 10, p. 0071467335, 2013.
[9] S. Borris, Total productive maintenance. McGraw-Hill New York, 2006.
[10] R. Thorat and G. T. Mahesha, “Improvement in productivity through TPM implementation,” Mater Today Proc, vol. 24, pp. 1508–1517, 2020.
[11] S. Sahu and S. K. Mishra, “Overall Equipment Effectiveness Improvement of Annealing Furnace by Implementation of Total Productive Maintenance (TPM)-A Case Study.,” 2017.
[12] R. Singh, A. M. Gohil, D. B. Shah, and S. Desai, “Total productive maintenance (TPM) implementation in a machine shop: A case study,” Procedia Eng, vol. 51, pp. 592–599, 2013.
[13] M. M. N. Haider and M. Rafiquzzaman, “Implementation of Total Productive Maintenance in a Jute Bag Industry: a Case Study,” Journal of Engineering Science, vol. 14, no. 1, pp. 137–149, 2023.
[14] E. Y. T. Adesta, H. A. Prabowo, and D. Agusman, “Evaluating 8 pillars of Total Productive Maintenance (TPM) implementation and their contribution to manufacturing performance,” in IOP conference series: materials science and engineering, IOP Publishing, 2018, p. 012024.
[15] J. C. Meca Vital and C. R. Camello Lima, “Total Productive Maintenance and the Impact of Each Implemented Pillar in the Overall Equipment Effectiveness,” International Journal of Engineering and Management Research, vol. 10, 2020.
[16] H. A. Prabowo, Y. B. Suprapto, and F. Farida, “The evaluation of eight pillars total productive maintenance (TPM) implementation and their impact on overall equipment effectiveness (OEE) and waste,” Sinergi, vol. 22, no. 1, pp. 13–18, 2018.
[17] J. Singh and H. Singh, “Justification of TPM pillars for enhancing the performance of manufacturing industry of Northern India,” International Journal of Productivity and Performance Management, vol. 69, no. 1, pp. 109–133, 2020.
[18] S. Kunio and N. Seiichi, “TPM for supervisors.” Productivity Press, Portland, 1992.
[19] X. Sun, “Implementing a Total Productive Maintenance Approach into an Improvement At S Company,” 2018.
[20] J. M. Nicholas, “Competitive manufacturing management: continuous improvement, lean production, customer-focused quality,” (No Title), 1998.
[21] D. Carnerud, C. Jaca, and I. Bäckström, “Kaizen and continuous improvement–trends and patterns over 30 years,” The TQM Journal, vol. 30, no. 4, pp. 371–390, 2018.
[22] M. Rossini, F. Audino, F. Costa, F. D. Cifone, K. Kundu, and A. Portioli-Staudacher, “Extending lean frontiers: a kaizen case study in an Italian MTO manufacturing company,” The international journal of advanced manufacturing technology, vol. 104, pp. 1869–1888, 2019.
[23] I. W. Rusdiana and D. Soediantono, “Kaizen and implementation suggestion in the defense industry: A literature review,” Journal of Industrial Engineering & Management Research, vol. 3, no. 3, pp. 35–52, 2022.
[24] I. Masaaki, “Kaizen: The key to Japan’s competitive success,” New York, ltd: McGraw-Hill, 1986.
[25] M. Dudin, E. Frolova, N. Gryzunova, and E. Shuvalova, “The Deming Cycle (PDCA) concept as an efficient tool for continuous quality improvement in the agribusiness,” Asian Soc Sci, vol. 11, no. 1, pp. 239–246, 2015.
[26] W. E. Deming, “Out of the crisis: Quality,” Productivity and Competitive Position, Massachusetts, USA, 1986.
[27] M. N. Dudin, O. O. Smirnova, N. V. Vysotskaya, E. E. Frolova, and N. G. Vilkova, “The deming cycle (PDCA) concept as a tool for the transition to the innovative path of the continuous quality improvement in production processes of the agro-industrial sector,” 2017.
[28] M. Jagusiak-Kocik, “PDCA cycle as a part of continuous improvement in the production company-a case study,” Production engineering archives, vol. 14, no. 14, pp. 19–22, 2017.
[29] G. Karuppusami and R. Gandhinathan, “Pareto analysis of critical success factors of total quality management: A literature review and analysis,” The TQM magazine, vol. 18, no. 4, pp. 372–385, 2006.
[30] S. Bajaj, R. Garg, and M. Sethi, “Total quality management: a critical literature review using Pareto analysis,” International Journal of Productivity and Performance Management, vol. 67, no. 1, pp. 128–154, 2018.
[31] R. S. Raman and Y. Basavaraj, “Quality improvement of capacitors through fishbone and pareto techniques,” International Journal of Recent Technology and Engineering, vol. 8, no. 2, pp. 2248–2252, 2019.
[32] M. S. Ab Talib, A. B. Abdul Hamid, and A. C. Thoo, “Critical success factors of supply chain management: a literature survey and Pareto analysis,” EuroMed Journal of Business, vol. 10, no. 2, pp. 234–263, 2015.
[33] S. A. Kumar and N. Suresh, Production and operations management. New Age International, 2006.
[34] D. D. Shinde, S. Ahirrao, and R. Prasad, “Fishbone diagram: application to identify the root causes of student–staff problems in technical education,” Wirel Pers Commun, vol. 100, pp. 653–664, 2018.
[35] M. Coccia, “The Fishbone diagram to identify, systematize and analyze the sources of general purpose Technologies,” Journal of Social and Administrative Sciences, vol. 4, no. 4, pp. 291–303, 2018.
[36] M. Hassan and I. M. Jalaludin, “Application of why-why analysis to improve predictive maintenance strategy for injection molding machine,” Information Technology Journal, vol. 15, no. 4, pp. 130–136, 2016.
[37] D. Little et al., “Preclinical tendon and ligament models: Beyond the 3Rs (replacement, reduction, and refinement) to 5W1H (why, who, what, where, when, how),” Journal of Orthopaedic Research®, vol. 41, no. 10, pp. 2133–2162, 2023.
