Improving the Effectiveness of Ampoule Filling Machines at PT X Using Total Productive Maintenance (TPM) and Overall Equipment Effectiveness (OEE)
Keywords:
Machine effectiveness, Overall Equipment Effectiveness, Pharmaceutical industry, Six Big Losses, Total Productive MaintenanceAbstract
This study aims to improve the effectiveness of ampoule filling machines at PT X, one of Indonesia’s leading pharmaceutical companies, through the implementation of Total Productive Maintenance (TPM) and Overall Equipment Effectiveness (OEE) measurement. The research is motivated by a decline in machine performance observed between January and August 2024, characterized by low production output, high downtime, and elevated defect rates. The study adopts a quantitative research approach, utilizing both primary and secondary data collected from 30 production batches through field observations, interviews, and documentation. OEE is evaluated based on its three main components—availability, performance, and quality—while production inefficiencies are identified using the Six Big Losses framework. Root cause analysis is conducted using a fishbone diagram, and improvement recommendations are developed in alignment with relevant TPM pillars. The implemented improvement actions include replacing frequently malfunctioning swing conveyor sensors and redesigning ampoule storage to reduce the risk of ampoule breakage caused by limited output space. The evaluation results indicate a significant improvement in OEE values following implementation, accompanied by reductions in downtime and product defects. These findings demonstrate that the integrated application of TPM and OEE evaluation is effective in optimizing machine performance and enhancing production efficiency in the sterile pharmaceutical manufacturing industry.
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