Hernanda, Chrestella Ayu (2020) Analisis Overall Equipment Effectiveness (OEE) pada Mesin Injection Molding A 09 di Perusahaan Packaging Surabaya. Sarjana thesis, Universitas Brawijaya.
Abstract
Industri manufaktur di Indonesia terus mengalami pertumbuhan dan perkembangan yang dilatarbelakangi oleh pemikiran manusia tidak terbatas. Salah satu perusahaan manufaktur yang senantiasa berkembang adalah perusahaan packaging di Surabaya yang memproduksi kemasan kosmetik berbahan dasar plastik. Dalam menjalankan produksinya, perusahaan packaging ini menghadapi permasalahan dimana terdapat beberapa hasil produk yang dibutuhkan dari departemen Injection Molding Machine (IMM) belum ready on hand sesuai dengan jadwal yang telah ditetapkan, yaitu satu hari sebelum jadwal assembly dimulai. Berdasarkan hasil observasi langsung dan diskusi dengan pihak terkait di perusahaan, permasalahan ini disebabkan oleh jumlah standar output produksi yang tidak tercapai karena terdapat downtime dari mesin injection molding yang digunakan. Departemen IMM sendiri memiliki 43 mesin injection molding yang telah digunakan sejak perusahaan berdiri, dimana mesin injection molding A 09 memiliki total downtime terbesar selama periode bulan Januari 2019 – Mei 2019. Oleh sebab itu, penelitian perlu dilakukan dengan tujuan untuk mengetahui efektivitas dari mesin injection molding A 09 serta memberikan rekomendasi perbaikan. Efektivitas dari mesin injection molding A 09 diketahui dengan menghitung nilai Overall Equipment Efectiveness (OEE) yang kemudian akan dibandingkan dengan standar global Japan Institute of Plant Maintenance (JIPM). Metode ini mengukur apakah suatu mesin atau peralatan dapat beroperasi secara normal atau tidak dengan mencakup tiga faktor, yaitu availability, performance, dan quality. Hasil perhitungan nilai OEE akan menunjukkan kondisi operasi keseluruhan dari suatu peralatan, serta mendefinisikan secara langsung perbedaan antara performa aktual dengan performa ideal. Setelah memperoleh nilai OEE, kemudian dilakukan perhitungan nilai Six Big Losses untuk mengetahui faktor kerugian apa saja yang paling berpengaruh terhadap nilai OEE tersebut. Akar penyebab dari faktor kerugian tersebut selanjutnya dapat diketahui dengan analisis 5-Why. Hasil penelitian menunjukkan bahwa rata-rata nilai OEE dari mesin injection molding A 09 adalah sebesar 73,40%. Rata-rata tersebut menunjukkan bahwa efektivitas mesin injection molding masih berada di bawah standar global JIPM yaitu sebesar 85%. Selanjutnya berdasarkan hasil perhitungan nilai Six Big Losses, dapat diketahui faktor kerugian utama yang paling berpengaruh terhadap rendahnya nilai OEE mesin injection molding, yaitu reduced speed loss dengan rata-rata persentase sebesar 15,32% dari total loading time. Kerugian berupa penurunan kecepatan mesin ini antara lain disebabkan oleh usia komponen mold yang sudah melebihi batas lifetimenya, mesin beroperasi secara kontinyu tanpa adanya istirahat, serta kerusakan kecil yang tidak ditangani dengan segera. Maka dari itu, beberapa rekomendasi perbaikan yang dapat diberikan adalah perusahaan sebaiknya memberikan pendidikan dan pelatihan kepada para operator mengenai cara mengatasi kegagalan kecil pada mesin yang digunakan, melaksanakan kegiatan inspeksi mesin pada awal tiap shift kerja, serta menerapkan kegiatan preventive maintenance. Dengan menerapkan beberapa rekomendasi perbaikan tersebut, diharapkan perusahaan packaging Surabaya dapat meminimalisir berbagai kerugian yang ada sehingga efektivitas dari mesin injection molding A 09 meningkatkan.
English Abstract
The manufacturing industry in Indonesia continues to experience growth and development based on unlimited human thought. One manufacturing company that is constantly developing is a packaging company in Surabaya that manufactures plastic-based cosmetic packaging. In running its production, this packaging company faces a problem where there are several products needed from the Injection Molding Machine (IMM) Department that are not ready on hand in accordance with the established schedule, which is one day before the start assembly schedule. Based on the results of direct observations and discussions with related parties in the company, this problem is caused by the amount of production output standards that are not achieved because there is machine downtime. The IMM Department itself has 43 injection molding machines that have been used since the company was founded, of which injection molding machine A 09 had the greatest total downtime during January 2019 – May 2019. Therefore, a study needs to be carried out in order to determine the effectiveness of the injection molding machine A 09 and provide recommendations for improvement. The effectiveness of the injection molding machine A 09 is determined by calculating the value of Overall Equipment Effectiveness (OEE) which will then be compared with the global standard by Japan Institute of Plant Maintenance (JIPM). This method measures whether a machine or equipment can operate normally or not by covering three factors, namely availability, performance, and quality. The OEE value calculation results will show the overall operating conditions of the equipment, as well as directly define the difference between actual performance and ideal performance. After obtaining the OEE value, then the calculation of the value of Six Big Losses is to determine which loss factors are most influential on the OEE value. The root cause of the loss factors can then be determined using 5-Why analysis. The result show that the average OEE value of the injection molding machine A 09 is 73.40%. These averages indicate that the effectiveness of injection molding machines is below the global standard by JIPM, which is 85%. Furthermore, based on the results of the calculation of Six Big Losses, it can be seen that the most influential factor on the low OEE value is reduced speed loss with an average percentage of 15.32%. Reduced speed loss is partly due to the age of the mold components that have exceeded its lifetime, the machine operates continuously without any breaks, and minor damage that is not handled immediately. Therefore, some recommendations for improvement that can be given are the company should provide education and training to operators on how to overcome minor failures on the machine used, carry out machine inspection activities at the beginning of each work shift, and implement preventive maintenance activities. By implementing these improvement recommendations, it is expected that the packaging company can minimize the various losses that exist so that the effectiveness of the injection molding machine A 09 increases.
Other obstract
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| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 0520070275 |
| Uncontrolled Keywords: | mesin injection molding, efektivitas, downtime, Overall Equipment Effectiveness, Six Big Losses injection molding machine, effectiveness, downtime, Overall Equipment Effectiveness, Six Big Losses |
| Subjects: | 600 Technology (Applied sciences) > 668 Technology of other organic products > 668.4 Plastics > 668.42 Polymerization plastics |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Bambang Septiawan |
| Date Deposited: | 28 Feb 2021 04:19 |
| Last Modified: | 17 Sep 2024 07:33 |
| URI: | http://repository.ub.ac.id/id/eprint/183412 |
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