Overall Equipment Effectiveness Improvement Strategy During Pandemic Covid19 Through the Integration of DMAIC And SMED Method

Indonesian car sales have dropped dramatically by 44% at the end of 2020 due to the impact of COVID-19 outbreak. It is make all car manufacturers to find a strategy to survive the business. The goal is to reduce losses in all production lines including the manufacturing process of components (parts) at all suppliers. The stamping process is the first process in car assembly. This process involved a high cost process, because it is associated with purchasing raw material, machinery and dies investment to make car bodies or components. Therefore, the effectiveness of stamping machine performance is very important to reduce cost. Overall Equipment Effectiveness (OEE) is known as a tool to overcome both cost and quality issues. This study aims to determine the causative factors as well as increase the OEE value on the 800T stamping machine at PT XYZ, through DMAIC (Define, Measure, Analyze, Improve, and Control) as frame work and the SMED (Single Minutes Exchange of Dies) method to reduce setup and adjustment losses. This integration successfully reduced dies change over time from 17.1 to 11.2 minutes and increased OEE from 62.4% to 78.2%.