Improvement Proposal to Reduce Six Big Losses Using the Overall Equipment Effectiveness (OEE) Method on the Filler Machine at PT PLNI

Abstract

ABSTRACT

This study proposes improvements to reduce Six Big Losses using the Overall Equipment Effectiveness (OEE) method on the Filler machine at PT PLNI. The problem identified is a low average OEE value of 64% from April to December 2025, below the company standard of 73%, mainly caused by high downtime during machine set up, which reduces productivity and customer satisfaction. This study aims to identify the causes of Six Big Losses, analyze how they affect OEE, and propose practical improvements. The method combines OEE calculation, Six Big Losses analysis, and root-cause analysis using a Fishbone Diagram and 5 Why. The measurement result shows an average OEE of 75.04%, indicating that machine performance is not yet optimal, mainly due to the low Performance Rate (83.38%). The dominant losses are Idling and Minor Stoppage (49.97%) and Reduced Speed Losses (31.58%). Fishbone and 5 Why analysis show that the main causes are Man (lack of training and discipline), Machine (no scheduled preventive maintenance), and Method (absence of a standard operating procedure).

Keywords: Six Big Losses, Overall Equipment Effectiveness (OEE), Downtime, Fishbone Diagram, 5 Whys Analysis, 5W+1H