Performance Optimization of Conventional Lathes in the Shipbuilding Industry Integrating OEE and TPM
Keywords:
Conventional Lathe, Overall Equipment Effectiveness, Shipyard, Six Big Losses, Total Productive MaintenanceAbstract
PT DPKB manufactures ship components such as M19 nuts and M20 bolts using conventional lathes. In its operations, the company faces challenges such as high downtime, rapid wear of cutting tools, coolant clogs, chip buildup, and unstable machine performance, all of which prolong production time and hinder the achievement of targets. This study aims to measure the effectiveness of conventional lathes, identify the dominant factors contributing to performance decline, and formulate strategies for improvement. The method used is a quantitative descriptive approach that integrates Total Productive Maintenance (TPM), Overall Equipment Effectiveness (OEE), the Six Big Losses, the Fishbone Diagram, and the 5W+1H analysis. The results show that the OEE for M19 nuts was 53.89% (Availability 76.40%, Performance Efficiency 77.97%, Quality 91.55%) and for M20 bolts was 19.30% (Availability 81.65%, Performance Efficiency 28.58%, Quality 82.58%), far below the Japan Institute of Plant Maintenance benchmark (85%). Operational efficiency is a key critical factor driven by speed-reduction losses and equipment failures resulting from a lack of preventive maintenance, clogged cooling channels, limited operator skills, and an unsupportive work environment. The novelty and contribution of this study lie in the formulation of a TPM framework tailored to heterogeneous shipyards, providing tactical guidance based on the 5W+1H action plan and the TPM pillars to optimize self-maintenance, periodic cleaning, and work standardization to improve the operational efficiency of shipyards.
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