Abstract
Overall Equipment Effectiveness (OEE) is a key indicator or measurement to measure operation performance and was introduced in Total Productive Maintenance (TPM). Since then, OEE has been evolved and widening it application until capable to measure overall global operation effectiveness. To stay competitive, OEE improvement is very crucial and many method and technique has been introduced and implemented. In this case study, it aims to improve OEE at bottles filling line in lube blending plant located in Melaka by focusing on reducing planned and unplanned downtime. To achieve that aim, lean six sigma methodology (LSS) was used. Define, Measure, Analyse, Improve, and Control (DMAIC) cycle was used as a framework and lean manufacturing (LM) will be used as tools and techniques to conduct the improvement activities. In Define, and Measure phase, the main OEE loss factor which are change over time and machine downtime were defined, primary (qualitative and quantitative) and secondary data had been measured. Root causes and potential causes were analysed in Analyse phase using cause and effect diagram (CED), and failure mode and effect analysis (FMEA). In Improve phase, Single minute exchange die (SMED) was used to reduce changeover process time while autonomous maintenance (AM) was executed to reduce machine downtime. Standards work was developed, and dashboard was used to control and monitoring OEE performance trend in Control phase. At the end of this case study, OEE result was calculated and compared with the OEE result before improvement, as result, it improved from 48.8% to 66.5%.
