Setyaningtyas, Meilania Dwi (2019) Analisis Overall Line Effectiveness (OLE) dan Upaya Peningkatan Efektivitas Lini Produksi KT24 dengan Total Productive Maintenance (TPM). Sarjana thesis, Universitas Brawijaya.
Abstract
PT. Bakrie Pipe Industries merupakan salah satu produsen pipa baja terkemuka di Indonesia yang memproduksi pipa baja ukuran 0,5 inchi hingga 24 inchi untuk berbagai keperluan seperti pipa air, minyak, gas, maupun konstruksi berstandar nasional ataupun internasional. Hasil observasi yang dilakukan pada Divisi Engineering dan Divisi Maintenance pada lini produksi KT24, diketahui bahwa target produksi pada beberapa project yang dikerjakan di lini produksi KT24 pada tahun 2017 tidak tercapai dan rata-rata waktu unexpected stopages lini produksi KT24 melebihi target maksimal perusahaan yaitu sebesar 6,76% yang seharusnya maksimal 2,89%. Maka dari itu diperlukan pengukuran efektivitas produksi dengan menggunakan metode Overall Line Effectiveness (OLE) untuk mengukur kinerja peralatan produksinya dan nantinya akan diberikan rekomendasi perbaikan agar efektivitas produksi dari lini produksi KT24 dapat meningkat dengan bantuan penerapan Total Productive Maintenance (TPM). Penelitian ini menerapkan metode OLE untuk mengukur efektivitas lini produksi yang bersifat kontinyu. Pada tahap awal dilakukan perhitungan nilai losses yang mempengaruhi efektivitas lini produksi. Losses adalah segala sesuatu yang menyebabkan mesin dan peralatan tidak berfungsi dengan semestinya atau menurun kemampuan produksinya. Perhitungan nilai losses dilakukan berdasarkan enam kategori losses (six big losses) yang nilainya mempengaruhi nilai efektivitas lini produksi. Selanjutnya dilakukan perhitungan nilai OLE untuk mengetahui besarnya efektivitas lini produksi. Setelah melakukan perhitungan nilai OLE dan melakukan identifikasi penyebab rendahnya nilai OLE, maka dapat dirancang rekomendasi perbaikan berdasarkan konsep TPM yang diharapkan dapat meningkatkan efektivitas lini produksi dan mencegah kemungkinan losses terjadi. Hasil penelitian menunjukkan bahwa rata-rata tingkat efektivitas lini produksi KT24 pada tahun 2017 adalah sebesar 64,93% dan losses yang mempengaruhi efektivitas lini produksi KT24 adalah reduced speed sebesar 42,12% atau 35.106 menit, breakdown losses sebesar 24,04% atau 20.306 menit, set-up and adjustment losses sebesar 19,61% atau 16.243 menit, idling and minor stopages sebesar 10,11% atau 8.427 menit, quality defect sebesar 4,11% atau sebesar 3.429 menit dan reduced yield sebesar 0% atau 0 menit. Beberapa penyebab terjadinya losses antara lain karena load produksi yang besar yang menyebabkan mesin bekerja lebih berat, pengaruh masa pakai komponen, pemeriksaan mesin hanya dilakukan secara visual, kualitas bahan baku yang kurang baik serta pengaruh umur mesin. Rekomendasi perbaikan yang diusulkan berdasarkan konsep TPM adalah dengan menambah jadwal pemeriksaan komponen mesin, pengadaan tempat untuk meletakkan set blok pisau, adanya pemilihan ulang supplier bahan baku, serta jika memungkinkan dijadwalkan untuk dilakukan overhaul lini produksi. Rekomendasi perbaikan ini diperkirakan akan mampu meningkatkan efektivitas lini produksi KT24 menjadi 67,45% atau naik sebesar 2,52%.
English Abstract
PT. Bakrie Pipe Industries is one of the leading steel pipe manufacturers in Indonesia that produces 0.5 inch to 24 inch steel pipes for various purposes such as water, oil, gas and national or international standard construction pipes. Observations made in the Engineering Division and Maintenance Division on the KT24 production line revealed that the production targets in several projects carried out in the KT24 production line in 2017 were not achieved and the average time unexpected stoppages of the KT24 production line exceeded the company's maximum target of 6,76% which should be 2,89%. Therefore, it is necessary to measure the effectiveness of production by using the Overall Line Effectiveness (OLE) method to measure the performance of production equipment and later to provide recommendations for improvement so that the production effectiveness of the KT24 production line can be increased with the help of Total Productive Maintenance (TPM) implementation. This study applies the OLE method to measure the effectiveness of a continuous production line. At the initial stage, calculation of the value of losses that affect the effectiveness of the production line is carried out. Losses are things that cause the engine and equipment not to function properly or decrease their production capability. Calculation of the value of losses is based on six categories of losses (six big losses) whose value affects the effectiveness of the production line. Then the OLE value is calculated to determine the effectiveness of the production line. After calculating the OLE value and identifying the causes of the low OLE value, recommendations for improvement can be designed based on the TPM concept which is expected to increase the effectiveness of the production line and prevent possible losses from occurring. The results showed that the average level of effectiveness of the KT24 production line in 2017 was 53.56% and losses that affected the effectiveness of the KT24 production line were reduced speed of 32.31% or 23,407 minutes, breakdown losses of 22.92% or 16,347 minutes and set-up and adjustment losses of 25% or 16,243 minutes, idling and minor stopages of 11,81% or 8.427 minutes, quality defect of 4,80% or 2.411 minutes and reduced yield of 0% or 0 minutes. Some of the losses caused by large production load which causes the engine to work more heavily, components’ lifetime, conducting machine inspection only visually, poor raw materials quality and the engine lifetime. The proposed improvement recommendations based on the TPM concept are to increase the schedule of inspection of engine components, procure a place to put the knife block set, the re-selection of raw materials suppliers, and if possible, schedule the overhaul of the production line. This improvement recommendation is expected to be able to increase the effectiveness of the KT24 production line to 67.45% or an increase by 2.52%.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | SKR/FT/2019/283/051904742 |
| Uncontrolled Keywords: | Overall Line Effectiveness (OLE), six big losses, Total Productive Maintenance (TPM)-Overall Line Effectiveness (OLE), six big losses, Total Productive Maintenance (TPM) |
| Subjects: | 600 Technology (Applied sciences) > 670 Manufacturing > 670.4 Special topics of manufacturing > 670.42 Factory operations engineering |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | soegeng sugeng |
| Date Deposited: | 14 Nov 2020 03:28 |
| Last Modified: | 14 Nov 2020 03:28 |
| URI: | http://repository.ub.ac.id/id/eprint/171252 |
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