As a fast-paced company in the personal care and home hygiene product industry, PT Reckitt Benckiser Indonesia (PT RB) develops innovative value creations for its customers. Its vision of a world where people are healthier and live better has made a difference by providing innovative solutions for healthier lives and happier homes, driven by consumer-led research that lies at the heart of its success.
PT RB’s business opportunities are strong (as the factory is one of the company’s worldwide manufacturing hubs); however, sustainability in improvement efforts and people involvement remain key concerns.
The Vision, Mission, and Values have been clearly defined, but these values need to be more deeply embedded on the shop floor to ensure a more sustainable Lean implementation.
One product line has an Overall Equipment Efficiency (OEE) average of less than 60% and continues to face challenges in improving workplace areas and conditions. The lack of visual standards and visual management in the production line makes analysis and day-to-day decision-making difficult.
PQM Consultants facilitated a TPM (Total Productive Maintenance) Methodology workshop for all management levels to ensure a shared understanding of TPM implementation. We focused on analyzing production performance (OEE) using existing data and addressing the key issues identified by RB’s management on the pilot model through the implementation of Autonomous Maintenance (AM) and Planned Maintenance (PM). The issues identified were:
Based on this analysis, PQM Consultants and the TPM team focused on achieving quick results in production through the following initiatives:
| KPI | Before | After |
|---|---|---|
OEE (End to End) |
28% |
30% |
OEE Production |
68% |
80% |
Lower Line Speed |
Avg: 3300 min/month (110 min/day) |
21% per day |
MTBF |
7 hours |
9 hours |
