Peningkatan Efektivitas Pada Mesin Welding Dengan Penerapan Konsep Total Productive Maintenance (Studi Kasus Pada PT Arthawenasakti Gemilang)

Cahyani, Lina Dwi (2014) Peningkatan Efektivitas Pada Mesin Welding Dengan Penerapan Konsep Total Productive Maintenance (Studi Kasus Pada PT Arthawenasakti Gemilang). Sarjana thesis, Universitas Brawijaya.

Abstract

PT Arthawenasakti Gemilang merupakan perusahaan manufaktur kaleng yang berlokasi di Karangploso, Malang. Diantara keseluruhan proses pembuatan kaleng, proses assembly pada line 20 memiliki jumlah waktu kerusakan yang tinggi terutama pada mesin welding. Upaya pengurangan jumlah waktu kerusakan mesin dapat dilakukan dengan menggunakan konsep Total Productive Maintenance. Total Productive Maintenance adalah suatu konsep pemeliharaan yang melibatkan seluruh pekerja yang bertujuan mencapai efektivitas pada seluruh sistem produksi melalui partisipasi dan kegiatan pemeliharaan (Suzaki, 2011). Tahap pertama yang dilakukan dalam penelitian ini adalah mengidentifikasi efektivitas mesin dengan menghitung nilai Overall Equipment Effectivitas (OEE) dari mesin welding. Tahap kedua adalah mengidentifikasi losses berdasarkan six big losses untuk mengetahui time losses terbesar yang mempengaruhi efektivitas mesin welding. Setelah diketahui losses terbesar yang terjadi, langkah selanjutnya adalah membuat diagram Fault Tree Analysis untuk mengetahui akar penyebab terjadinya kerusakan dari mesin welding. Setelah itu dilakukan perhitungan probabilitas kegagalan untuk mengetahui komponen yang memiliki frekuensi terjadinya kegagalan paling tinggi. Tahap terakhir adalah pemberian rekomendasi perbaikan berdasarkan delapan pilar TPM untuk komponen yang memiliki probabilitas kegagalan tertinggi. Berdasarkan hasil penelitian diketahui mesin welding memiliki rata-rata nilai OEE sebesar 80,46%. Nilai itu masih dibawah standar World Class OEE yang bernilai 85,00% sehingga menunjukkan bahwa perlu dilakukan evaluasi untuk meningkatkan efektivitas mesin welding. Kemudian hasil identifikasi six big losses menunjukkan bahwa losses yang terbesar adalah reduced speed losses dan breakdown losses. Kedua losses tersebut disebabkan karena terjadinya kegagalan mesin. Penggambaran diagram Fault Tree Analysis menunjukkan kegagalan mesin welding disebabkan oleh empat komponen utama yaitu feeder, sheet transporter, conveyor chain, dan current. Berdasarkan perhitungan probabilitas kegagalan diketahui can body transporter merupakan komponen yang memiliki probabilitas kegagalan tertinggi. Usulan rekomendasi perbaikan yang diberikan untuk mengurangi breakdown losses berdasarkan delapan pilar TPM yaitu melakukan pengecekan setting komponen secara keseluruhan sebelum memulai proses produksi, melakukan pembersihan roller setiap pergantian shift, melakukan pengecekan komponen setiap satu bulan sekali, memberikan pelumas secara berkala pada chain, spring, bearing, dan roller, memberikan pelatihan singkat kepada operator, membuat Standart Operasional Procedure proses pengecekan mesin serta membuat lembar pengecekan harian dan bulanan untuk mencatat dan memantau kondisi mesin.

English Abstract

Arthawenasakti Gemilang Ltd is a manufacturing company that produces tin plate located in Karangploso, Malang. Among all the processes, 20th assembly line has the highest time of failure especially welding machine. Reducing the amount of time the failure machine can be done by using the concept of Total Productive Maintenance. Total Productive Maintenance is a maintenance concept that involves all employees aimed at reaching effectiveness of the entire production system through participation and maintenance activities (Suzaki, 2011). The First step of this research is identifying the machine effectiveness by calculating the number Overall Equipment Effectiveness (OEE) from welding machine. The second step is identifying losses from six big losses to calculate the biggest time losses which influencing the machine effectiveness. After the biggest losses have known, the next step is making Fault Tree Analysis diagram to find the roots of failure on machine welding followed by calculating failure probability to know which component that has the highest frequency of failure. The last step is giving improvement recommendations based on eight pillars of TPM. Based on the research result known that welding machine has average number OEE of 80,46%. This number is still under the standard of World Class OEE of 85,00%. It is shows that welding machine needs to be evaluated to improve the effectiveness. It is also known that the biggest losses are reduced speed losses and breakdown losses. Both losses is caused by failure machine. Fault Tree Analysis diagram shows failure of welding machine caused by four main components which are feeder, sheet transporter, conveyor chain, and current. Based on the failure probability calculation, it is found that can body transporter is a component that has the highest frequency of failure. The suggested recommendations to reduce breakdown losses based on eight pillars of TPM are thoroughly checking of component setting before starting production process, cleaning the roller in early shift work, checking the component every month, apply lubricant regularly on chain, spring, bearing, and roller, giving a short training for operators, making a Standard Operational Procedure of checking machine proses, and making a daily and monthly checking sheet to record and monitoring machine condition.

Item Type: Thesis (Sarjana)
Identification Number: SKR/FT/2014/500/051405265
Subjects: 600 Technology (Applied sciences) > 670 Manufacturing
Divisions: Fakultas Teknik > Teknik Industri
Depositing User: Hasbi
Date Deposited: 29 Aug 2014 08:57
Last Modified: 18 Nov 2021 03:50
URI: http://repository.ub.ac.id/id/eprint/142809
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