Our Successful Projects
Total Productive Maintenance Implementation PT Kao Indonesia
Client
PT Kao Indonesia
Topic
Total Productive Maintenance
Overview
PT Kao Indonesia faces the harsh business consumer goods environment with several challenges such as Stringent Demand on Quality, Lower Cost (essential for survival), Speed (Shorter Delivery Time), Flexible Production System (Responsive to Demand), Safety, and environmentally friendly.
Solution
In 2009, PQM Consultants started facilitating the fundamental pillars of TPM (Total Productive Maintenance) implementation such as Focused Improvement and Autonomous Maintenance. The purpose of the TPM is to improve the reliability and flexibility of equipment toward customer demands and requirements.
Employees have undertaken some Kaizen initiatives, and the standard has been maintained during TPM Implementation, such as in the Skin Care factory, eliminating vigilant errors, reducing hot-air station and heating station troubles, quick setting up of eye-mark sensors and eliminating unnecessary adjustment.
Result
The average increase in Overall Equipment Effectiveness (OEE) across the three factories is 12%. Downtime duration has been reduced to 20%, and the number of minor stoppages is now below 10 times per day. Additionally, productivity has increased by approximately 30%.
Kao Indonesia engaged in the business of consumer goods (consumer goods) is broadly grouped into the following categories: skin care (including soaps and facial treatments), Human healthcare (sanitary napkins), and household products (fabrics homecare).
Achievement
- Overall Equipment Efficiency increase 12%
- Downtime reduction : 20%
- Productivity increase : 30%
