This document discusses key performance indicators for measuring machine efficiency, including operational efficiency (OE), utilization indices, capacity measures, and production efficiency. It provides examples of calculating these metrics based on production data for a bottling line, including total time, operational time, planned/unplanned stoppages, production time, and effective time. A high machine OE results in higher output, increased company sales and profits, and higher employee earnings and bonuses.

1. PAMCO
oleh Bagoes Soehariadji
● PLANT & MACHINE CONTROL
• SUATU SYSTEM UNTUK MEMONITOR KONDISI
MESIN
* EFFICIENCY ( Performance Mesin )
* UTILIZATION ( Penggunaan Mesin )

2. P
Production Time
OVERALL TIME ANALYSIS
T Total Time
Unavailabl
e
Time
A Available Time
U Used Time
Available Unused
Time
O
Operational Time
Planned Non-
Operational Time
Routine
Production Stoppages
E Effective
Time
Unexpected
Stoppages
- Statutory & Religious Holidays
- Weekends and Shifts not Worked
- Enforced Factory Shutdowns
- No Production Orders
- Planned Maintenance / Modifications
- Planned Tests without Production (Production Trials)
- Start-up, Shutdown & Change Over
- Cleaning, Loading / Unloading, Machine Setting
- Meals, breaks, Rest Periods
- Shortage of Materials/Services/Operators
- Quality Defect
- Machine Breakdown

3. TOTAL TIME
● TOTAL TIME ( T ) = Total Waktu
* 1 Tahun = 52 minggu
* 1 Minggu = 21 shift
= 168 jam
T Total Time

4. AVAILABLE TIME
● AVAILABLE TIME (A)
~ Waktu tersedia
= Total Time - Unavailable Time
( Total waktu ) ( Waktu yang tidak tersedia )
Unavailable Time :
Hari Libur Nasional
Hari Minggu
Minggu Lebaran
T Total Time
Unavailabl
e
Time
A Available Time

5. USED TIME
● USED TIME (U)
~ Waktu yang digunakan
= Available Time - Available Unused Time
( waktu tersedia ) ( waktu yang tidak digunakan )
Available Unused Time :
* Tidak ada Planning Produksi
(No Shop Order)
Unavailabl
e
Time
A Available Time
U Used Time Available Unused Time

6. OPERATIONAL TIME
● OPERATIONAL TIME (O)
~ Waktu operational
= Used Time - Planned non Operational Time
( waktu yang digunakan ) ( waktu stop direncanakan )
Planned Non Operational Time :
* Planned Maintenance/Modification (Overhaul)
* Development Trial
* Shalat Jumat
U Used Time Available Unused Time
O
Operational Time
Planned
Non-operational Time

7. P
O
Operational Time
Planned
Non-operational Time
Production
Time
PRODUCTION TIME
● PRODUCTION TIME ( P )
~ Waktu produksi
= Operational Time - Routine Stoppages
(waktu operational ) ( waktu stop rutin )
Routine Stoppages :
* Kebersihan , Persiapan Produksi
* Change Over, Machine Setting
* Istirahat (Makan)
Routine
Production Stoppages

8. P
Production
Time
E Effective
Time
unexpected
stoppages
EFFECTIVE TIME
● EFFECTIVE TIME ( E )
~ Waktu efektif /menghasilkan
= Production Time - Unexpected Stoppages
( waktu produksi ) ( waktu stop tak terduga )
Unexpected Stoppages :
Kerusakan mesin , tidak ada operator
Tidak ada material , listrik/angin/air,dll
Quality reason, accident
Routine
Production Stoppages

9. OPERATIONAL EFFICIENCY
P Production
Time
T Total Time
Unavailable
Time
A Available Time
U Used Time Available Unused Time
O Operational Time Planned
Non-operational
Time
Routin
e
Production
Stoppages
E Effective
Time
unexpecte
d
stoppage
s
X 100 %
Effective Time (E)
Operational Time (O)
Operational Efficiency measures how efficiently a machine has been
operated by the production department over the time it was planned to run.
OE =
X 100 %
Good Output (Actual Production)
Standard Speed
OE =

10. UTILISATION INDICES
AVAILABLE UTILISATION is a measures of how an asset is planned to be used in the time that it
is normally operated when running at its current efficiency.
X 100 %
Operational Time (O)
Available Time (A)
AU =
OPERATIONAL UTILISATION is a measures of how an asset is planned to be used in the full time
available during a period.
X 100 %
Operational Time (O)
Total Time (T)
OU =
P Production
Time
T Total Time
Unavailable
Time
A Available Time
U Used Time Available Unused Time
O Operational Time Planned
Non-operational
Time
Routin
e
Production
Stoppages
E Effective
Time
unexpecte
d
stoppage
s

11. 24 hr
110
34 hr
Routine Stop
& unexpected
stop
Planned Stop
OE = 110/144 * 100 = 76.4 %
Utilization = 144/168 * 100 = 85.7
%
Yang mungkin terjadi :
1. C/O is recorded into Planned Stop (Shut Down Loss)
2. PM execution is longer than planned
3. Start Up Loss on Sunday is not recorded due to zero output
4. Breakdown more than 1 shift is not recorded (no LPH) due to zero output
5. Breakdown loss is recorded as PM
168 hr
(1 week)
48 hr
110
10 hr
Planned Stop
OE = 110/120 * 100 = 91.6 %
Utilization = 120/168 * 100 = 71.4
%
Rutin Stop &
unexpected
stop

12. CAPACITY MEASURES
AVAILABLE CAPACITY measures the output that can be expected from a machine when operated at
estimated efficiency in a full year taking account of local holidays and shut - downs and other times when
it will not be available.
Standard Speed x OE
100 x Available Time per year
AC =
Standard Speed x OE
100 x Total Time per year
MC =
MAXIMUM CAPACITY measures the potential or maximum output that could be obtained from a
machine when operated at a stated efficiency over the maximum time in a year (vic. 8760 hours)

13. Loss Time = Total Time - Effective Time
( 480 menit )
Effective Time = TOTAL OUTPUT : SPEED
( 32 Fib. ) ( 100 bag )
= ( 32 X 1200 bag ) : 100 bag
= 38.400 bag : 100 bag
= 384 menit
Loss time = 480 menit - 384 menit
= 96 menit
PERHITUNGAN LOSS

14. O = Total time - plan stop
Tangga
l
7-Feb-03
Dina
s
Pagi
Produc
t
BIA 24 x 300 ml
bottle
Speed /
min
54 ( 6 x 9 )
Output ( doos
)
810
Output ( pcs
)
19,440
TOTAL TIME ( T ) 480 100.
0
%
Planned non
operational
-
Trial
-
Overhaul
OPERATIONAL TIME ( O )
minutes
480 100.
0
%
Routine
stop
- Ganti produk /
C.O
- Kebersihan /
cleaning
20 4.
2
%
- Shalat
Jum'at
30 6.
3
%
- Persiapan
produksi
20 4.
2
%
Tota
l
70 14.
6
%
PRODUCTION TIME
( P ) minutes
410 85.
4
% P = Opr time - Routine stop
STOP TAK
TERDUGA
Bukan karena
mesin
- Tidak ada bahan /
kecap
15 3.
1
%
- Tidak ada
operator
- Tidak ada listrik /
angin
10 2.
1
%
- Bahan
afkir
Sub total 1 25 5.
2
%
Bukan karena
mesin
- Tidak ada
karton
- Tidak ada
botol
- Tidak ada
label
- Tidak ada
tutup
- Tidak ada
lem
- Kecap tumpah
dikonveyor
15 3.
1
%
- Kecap turun
lambat
10 2.
1
%
- Label
miring
- Stempel
keteter
-
Conveyor Sub total 2 25 5.
2
%
Tota
l
120 10.
4
%
RUNNING TIME ( R ) 360 75.
0
% R = Prod time - stop tak terduga
Time Adjustment / waktu penyesuaian 0 0.
0
%
EFFECTIVE TIME ( E ) 360 75.
0
% ( output / speed mesin )
PRODUCTION UTILIZATION 100 % ( O/T
)
OPERATIONAL
EFFICIENCY
75 % ( E/O
)

15. PAMCO
● MENCATAT/MENULIS PAMCO YANG BENAR :
DINAS : ……………….
HARI : ……………….
TANGGAL : ……………….
NAMA : ……………….
NIP : ……………….
PRODUCT : ……………….
OUTPUT : ……………….
MENULISKAN MASALAH MENGGUNAKAN
ANGKA BUKAN PAKAI SIMBUL ( V / X )

16. GRAVITY FILLING LINE - 1 , 2
O = Total time - plan
stop
Tangga
l
7-Feb-03
Dina
s
Pagi
Produc
t
BIA 24 x 300 ml bottle
Speed / min 54 ( 6 x 9 )
Output ( doos
)
810
Output ( pcs
)
19,440
TOTAL TIME ( T
)
480 100.0 %
Planned non
operational
-
Trial
- Overhaul
OPERATIONAL TIME ( O )
minutes
480 100.0 %
Routine stop
- Ganti produk /
C.O
- Kebersihan /
cleaning
20 4.2 %
- Shalat Jum'at 30 6.3 %
- Persiapan
produksi
20 4.2 %
Tota
l
70 14.6 %
PRODUCTION TIME
( P ) minutes 410 85.4 % P = Opr time - Routine
stop
STOP TAK
TERDUGA
Bukan karena
mesin
- Tidak ada bahan / kecap 15 3.1 %
- Tidak ada operator
- Tidak ada listrik / angin 10 2.1 %
- Bahan afkir
Sub total 1 25 5.2 %
Bukan karena
mesin
- Tidak ada
karton
- Tidak ada botol
- Tidak ada label
- Tidak ada tutup
- Tidak ada lem
- Kecap tumpah dikonveyor 15 3.1 %
- Kecap turun lambat 10 2.1 %
- Label
miring
- Stempel keteter
-
Conveyor Sub total 2 25 5.2 %
Total 120 10.4 %
RUNNING TIME ( R ) 360 75.0 % R = Prod time - stop tak terduga
Time Adjustment / waktu
penyesuaian
0 0.0 %
EFFECTIVE TIME ( E
)
360 75.0 % ( output / speed mesin
)
PRODUCTION UTILIZATION 100 % ( O/T
)
OPERATIONAL
EFFICIENCY
75 % ( E/O
)

17. EFFICIENCY INDICES
X 100 %
EFFECTIVE TIME (E)
PRODUCTION TIME (P)
PRODUCTION EFFICIENCY measures how efficiently a machine has
been operated by the production department in the time that it was within
their control and could have been run productively.
PE =

18. UTILISATION INDICES
AVAILABLE UTILISATION is a measures of how an asset is planned to be used in the time that it
is normally operated when running at its current efficiency.
X 100 %
OPERATIONAL TIME (O)
AVAILABLE TIME (A)
AU =
OPERATIONAL UTILISATION is a measures of how an asset is planned
to be used in the full time available during a period.
EFFECTIVE UTILISATION is a measures of how much output can be obtain from an asset in
the full time available when running at its current efficiency. As it is a very severe measure of its use it
will normally only be of value for a company
assessing how its plant are being utilised internationally over the long term.
X 100 %
OPERATIONAL TIME (O)
MAXIMUM TIME (A)
OU =
X 100 %
EFFECTIVE TIME (O)
MAXIMUM TIME (A)
EU =

19. PAMCO
● DAMPAK POSITIF OE MESIN TINGGI :
OUTPUT TINGGI
PERUSAHAAN PENJUALAN MENINGKAT
( PROFIT MENINGKAT )
KARYAWAN PENDAPATAN MENINGKAT
( PREMI AKAN MENDAPAT BESAR )