v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables ix
List of Figures x
List of Abbreviations, Symbols and Nomenclatures xi
CHAPTER 1: INTRODUCTION 1
1.1 Problem Statement
3 1.2
Objectives 3
1.3 Scope
4 1.4
Organization of the report 4
CHAPTER 2: LITERATURE REVIEW 5
2.1 Product Manufacturing
5 2.1.1 Production
5 2.1.2 Productivity
6 2.1.3 Productivity Improvement
6 2.2
Work Standardization 7
2.2.1 Cycle Time 8
2.2.2 Takt Time 8
2.3 Machine Efficiency
8 2.3.1 Maintenance
9 2.3.2 Preventive Maintenance PM
9 2.3.2.1 The Benefits of PM
10 2.3.3 Total Productive Maintenance TPM
11 2.3.3.1 The Benefits of TPM
15 2.3.4 Overall Equipment Effectiveness OEE
16
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2.3.4.1 The Benefits of OEE 21
2.3.5 Bottlenecks 22
2.3.6 Uses and Misuse of OEE 23
2.3.6.1 The uses of OEE 23
2.3.6.2 The Misuses of OEE 24
2.3.7 Benchmarking 25
CHAPTER 3: REASEARCH METHODOLOGY 26
3.1 Overview of Methodology
26 3.1.1 The Process Planning Flow Chart
28 3.1.2 The Explanation of Process Planning Flow Chart
29 3.1.2.1 Problem statement identification
29 3.1.2.2 Literature review
29 3.1.2.3 Study the machine performance at Jati Beringin Sdn. Bhd. 30
3.1.2.4 Propose and Implementation an improvement plans 30
3.1.2.5 Monitoring 31
3.1.2.6 Analyze the data 31
3.2 Overall Equipment Effectiveness
31 3.2.1 Know the OEE Factors
31 3.2.1.1 Plant Operating Time
32 3.2.1.2 Planned Production Time
32 3.2.1.3 Operating Time
32 3.2.1.4 Net Operating Time
32 3.2.2 Attacking the Six Big Losses
34 3.2.2.1 Defining the Six Big Losses
34 3.2.3 Analyze the Data
36 3.2.3.1 Observation
36 3.2.3.2 Operational Cycle Time
36 3.2.3.3 Time Observation Form
37 3.2.3.4 Product Demand
38 3.2.4 Calculating the OEE
38
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CHAPTER 4: COMPANY BACKGROUND 39
4.1 Factory Address
39 4.2
Company Background 39
4.3 Business Nature
40 4.4
Organization Chart 40
CHAPTER 5: RESULT AND DISCUSSION 41
5.1 Result and Discussion
41 5.2
Analysis of Current Data 42
5.2.1 Downtime and Scrap data 43
5.2.2 Machine Operating Time 43
5.2.3 Current Standard Operation Process SOP 45
5.2.4 Operation Cycle Time 48
5.2.5 Daily Demand 49
5.2.6 OEE Calculation for Current Data 50
5.3 Propose and Improvement
52 5.3.1 Improvement Plans
52 5.4
Analysis of After Improvement 53
5.4.1 New SOP 53
5.4.2 Operation Cycle Time of New SOP 55
5.4.3 New Daily Demand after Implement 56
5.4.4 OEE Calculation for Implemented Data 57
5.5 Discussion
58
CHAPTER 6: CONCLUSION AND FUTURE RECOMMENDATION 60
