Overall Equipment Effectiveness to Increase Productivity of Injection Molding Machine: A Case Study in Plastic Manufacturing Industry


  • Sunadi Sunadi Mercu Buana University
  • Humiras Hardi Purba Mercu Buana University
  • Else Paulina Mercu Buana University




Overall Equipment Effectiveness, company productivity, injection molding machine, plastic manufacturing industry


In line with the unstable market conditions in Indonesia, especially the plastic manufacturing industry, the companies need to be well prepared to survive. There were two research goals. First, it was to find out why the Overall Equipment Effectiveness (OEE) rate at the company did not meet the expected standard. Second, it was to determine what improvement should be made to increase the OEE for the machine. The research applied a case study in one of the plastic manufacturing industries located in Tangerang, Indonesia. It focused on the performance of Toshiba injection molding machine number 42/IS 450 GSW. The analysis was performed by applying Failure Mode and Effect Analysis (FMEA) with support from other tools such as Pareto chart, Cause and Effect Diagram (CED), and six big losses. By following the whole framework of the research, it finds causes of why the OEE does not meet the target. Then, from the results, it can be concluded that the implementation of the methods has a positive impact on the company. The OEE rate increases from an average of 26,43% to 78,87%. It means the OEE rate has achieved the company target of 75%.


Plum Analytics


Ahuja, I. P. S., & Singh, P. (2012). Application of analytical hierarchy process for justification of TPM implementation in manufacturing organisations. International Journal of Technology, Policy and Management, 12(1), 37-47.

Badli Shah, M. Y. (2012). Total Productive Maintenance: A study of Malaysian automotive SMEs. In Proceedings of the World Congress on Engineering (pp. 1460-1464).

Benjamin, S. J., Murugaiah, U., & Marathamuthu, M. S. (2013). The use of SMED to eliminate small stops in a manufacturing firm. Journal of Manufacturing Technology Management, 24(5), 792–807.

Biro Pusat Statistik (BPS). (2018). Laju pertumbuhan indsutri makanan dan minuman. Retrieved from https://lokadata.beritagar.id/chart/preview/laju-pertumbuhan-indsutri-makanan-dan-minuman-2013-2018-1563426644#

Ćatić, D., & Glišović, J. (2019). Failure Mode, Effects and Criticality Analysis of mechanical systems’ elements. Mobility and Vehicle Mechanics, 45(3), 25-39.

Cheah, C. K., Prakash, J., & Ong, K. S. (2020). Overall Equipment Effectiveness: A review and development of an integrated improvement framework. International Journal of Productivity and Quality Management, 30(1), 46-71.

Chong, K. E., Ng, K. C., & Goh, G. G. G. (2015). Improving Overall Equipment Effectiveness (OEE) through integration of Maintenance Failure Mode and Effect Analysis (Maintenance-FMEA) in a semiconductor manufacturer: A case study. In 2015 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM) (pp. 1427-1431). IEEE.

Chrysler LLC, Ford Motor Company, & General Motors Corporation. (2008). Potential Failure Mode and Effect Analysis (FMEA) (4th ed.). AIAG

Dal, B., Tugwell, P., & Greatbanks, R. (2000). Overall Equipment Effectiveness as a measure of operational improvement – A practical analysis. International Journal of Operations & Production Management, 20(12), 1488-1502.

Darsin, M. (2020). Aplikasi Overall Equipment Effectiveness (OEE) dalam upaya mengatasi tingginya downtime pada stasiun ketel di PG X Jawa Timur. Multitek Indonesia, 13(2), 95-103.

Dunford, R., Su, Q., & Tamang, E. (2014). The pareto principle. The Plymouth Student scientist, 7(1), 140-148.

Gandhi, D. N., & Deshpande, V. (2018). A review of TPM to implement OEE technique in manufacturing industry. Industrial Engineering Journal, XI(6), 36-46.

Gidey, E., Beshah, B., & Kitaw, D. (2014). Review on the evolving relationship between quality and productivity. International Journal for Quality Research, 8(1), 47-60.

Gupta, A. K., & Garg, R. K. (2012). OEE improvement by TPM implementation: A case study. International Journal of IT, Engineering and Applied Sciences Research, 1(1), 115-124.

Lazim, H. M., Salleh, M. N., Subramaniam, C., & Othman, S. N. (2013). Total Productive Maintenance and manufacturing performance: Does technical complexity in the production process matter. International Journal of Trade, Economics and Finance, 4(6), 380-383.

McDermott, R. E., Mikulak, R. J., & Beauregard, M. (2009). The basic of FMEA (2nd ed.). CRC Press

Mad Lazim, H., & Ramayah, T. (2010). Maintenance strategy in Malaysian manufacturing companies: A Total Productive Maintenance (TPM) approach. Business Strategy Series, 11(6), 387-396.

Mardono, U., Rimawan, E., Pratondo, T., & Saraswati, I. (2019). An analysis of the effect of elimination of six big losses on increasing profitability in steel rolling mill companies. International Journal of Mechanical and Production Engineering Research and Development, 9(2), 387-398.

Nakajima, S. (1988). Introduction to TPM: Total Productive Maintenance. Productivity Press, Inc.

Nasution, M. N. (2005). Manajemen mutu terpadu. Ghalia Indonesia.

Nallusamy, S., & Majumdar, G. (2017). Enhancement of Overall Equipment Effectiveness using Total Productive Maintenance in a manufacturing industry. International Journal of Performability Engineering, 13(2), 173-188.

Nurprihatin, F., Angely, M., & Tannady, H. (2019). Total Productive Maintenance policy to increase effectiveness and maintenance performance using Overall Equipment Effectiveness. Journal of applied Research on Industrial Engineering, 6(3), 184-199.

Prabowo, H. A., Suprapto, Y. B., & Farida, F. (2018). The evaluation of eight pillars Total Productive Maintenance (TPM) implementation and their impact on Overall Equipment Effectiveness (OEE) and waste. Sinergi, 22(1), 13-18.

Pinjar, M. V. N., Shivakumar, S., & Patil, G. V. (2015). Productivity improvement through Single Minute Exchange of Die (SMED) technique. International Journal of Scientific and Research Publications, 5(7), 1-9.

Reddy, A. S. N., Rao, P. S., & Rajyalakshmi, G. (2016). Productivity improvement using time study analysis in a small scale solar appliances industry-A case study. ARPN Journal of Engineering and Applied Sciences, 11(1), 666-674.

Ranjan, R., & Mishra, A. (2016). Evaluation and optimization of Overall Equipment Effectiveness on a pasting machine in a battery manufacturing industry. International Journal of Performability Engineering, 12(6), 503-512.

Rusman, M., Parenreng, S. M., Setiawan, I., Asmal, S., & Wahid, I. (2019). The Overall Equipment Effectiveness (OEE) analysis in minimizing the Six Big Losses: An effort to green manufacturing in a wood processing company. IOP Conference Series: Earth and Environmental Science, 343, 012010

Salonen, A., & Deleryd, M. (2011). Cost of poor maintenance: A concept for maintenance performance improvement. Journal of Quality in Maintenance Engineering, 17(1), 63-73.

Samuel, A. U., Oyawale, F., & Fayomi, O. S. I. (2019). Analysis and reduction of waste in beverage industries using Pareto principle and value stream mapping. Journal of Physics: Conference Series, 1378, 1-13.

Sangameshwran, P., & Jagannathan, R. (2002). HLL’s manufacturing renaissance. Indian Management, November, 30-35.

Shakil, S. I., & Parvez, M. (2018). Application of lean manufacturing in a sewing line for improving Overall Equipment Effectiveness (OEE). American Journal of Industrial and Business Management, 8(9), 1951-1971.

Shirose, K. (1995). TPM team guide. Productivity Press.

Singh, R., Gohil, A. M., Shah, D. B., & Desai, S. (2013). Total Productive Maintenance (TPM) implementation in a machine shop: A case study. Procedia Engineering, 51, 592-599.

Singh, M., & Narwal, M. (2017). Measurement of Overall Equipment Effectiveness (OEE) of a manufacturing industry: An effective lean tool. International Journal of Recent Trends in Engineering and Research, 3(5), 268-275.

Siregar, A. R., Purba, H. H., & Aisyah, S. (2017). Measuring Overall Equipment Effectiveness (OEE) palm oil mill in Indonesia. International Journal of Recent Trends in Engineering and Research, 3(12), 164-170.

Supriyadi, S., Ramayanti, G., & Afriansyah, R. (2017). Analisis Total Productive Maintenance dengan metode Overall Equipment Effectiveness dan Fuzzy Failure Mode and Effects Analysis. Sinergi, 21(3), 165-172.

Susilo, C. F., & Andika, A. (2016). Overall Equipment Effectiveness improvement with Total Productive Maintenance method. In 2016 Global Conference on Business, Management and Entrepreneurship.

Sutardi, A., & Budiasih, E. (2011). Pengolahan data penjualan buku menggunakan metode klasifikasi ABC (Diagram pareto) untuk mengidentifikasi kategori buku yang banyak diminati pembaca (Studi Kasus: PT. Elex Media Komputindo). Konferensi Nasional ICT-M Politeknik Telkom.

Tobe, A. Y., Widhiyanuriyawan, D., & Yuliati, L. (2018). The integration of Overall Equipment Effectiveness (OEE) method and lean manufacturing concept to improve production performance (Case study: Fertilizer producer). Journal of Engineering and Management in Industrial System, 5(2), 102-108.

Waghmare, S. N., Raut, D. N., Mahajan, S. K., & Bhamare, S. S. (2014). Failure Mode Effect Analysis and Total Productive Maintenance: A review. International Journal of Innovative Research in Advanced Engineering, 1(6), 183-203.

Wahyudin, B. I. S., & Hasibuan, S. (2019). Analysis for enhancing quality and productivity using Overall Equipment Effectiveness and statistical process control in manufacturing industry case study: Manufacturing industry sport shoes in Tangerang region. International Journal of Innovative Science and Research Technology, 4(12), 108-114.

Xu, Z., & Dang, Y. (2020). Automated digital cause-and-effect diagrams to assist causal analysis in problem-solving: A data-driven approach. International Journal of Production Research, 58(17), 5359-5379.

Yusuf, B., Rahman, A., & Himawan, R. (2015). Analisa Overall Equipment Effectiveness untuk memperbaiki sistem perawatan mesin DOP berbasis Total Productive Maintenance (Studi kasus: PT XYZ–Malang). Jurnal Rekayasa dan Manajemen Sistem Industri, 3(1), 99-109.

Zammori, F., Braglia, M., & Frosolini, M. (2011). Stochastic Overall Equipment Effectiveness. International Journal of Production Research, 49(21), 6469-6490.






Abstract 978  .
PDF downloaded 979  .