Putera, Nova Aditya Nugraha and Dr. Eng. Oke Oktavianty, S.Si, MT. (2022) Analisis Overall Equipment Effectiveness (OEE) Dalam Meningkatkan Efektivitas Mesin Air Jet Loom Melalui Pendekatan 4 Pilar Total Productive Maintenance (TPM). Sarjana thesis, Universitas Brawijaya.
Abstract
Sektor industri saat ini sedang berlomba-lomba untuk meningkatkan teknologi dan sistem produksi agar menjadi lebih efektif dan efisien. Dimana ketika sistem produksi dari perusahaan bisa efektif dan efisien maka akan berdampak positif baik dari segi kualitas produk yang dihasilkan maupun target produksi yang mudah untuk dicapai. PC Gabungan Koperasi Batik Indonesia merupakan perusahaan yang bergerak di bidang tekstil, sistem pemesanan dari perusahaan ini sendiri ada dua jenis yaitu make to stock dan make to order. Tetapi dalam proses produksi masih banyak ditemukan produk cacat yang disebabkan karena tingginya downtime mesin Air Jet Loom yang digunakan dalam proses produksi. Maka dari itu dibutuhkan identifikasi penyebab utama tingginya downtime pada mesin produksi yang digunakan dibantu dengan menggunakan metode Total Productive Maintenance dan memberikan rekomendasi perbaikan untuk meningkatkan efektivitas dari mesin. Pada penelitian ini metode Total Productive Maintenance yang digunakan adalah OEE (Overall Equipment Effectiveness) dimana metode ini digunakan untuk menghitung nilai efektivitas dari suatu mesin dan dilanjutkan dengan perhitungan losses terbesar menggunakan metode Six Big Losses. Tahap perhitungan OEE dimulai dengan melakukan perhitungan Availability Rate, Perfomance Rate, dan Rate of Quality. Guna data yang dibutuhkan untuk menemukan nilai persentase OEE. Setelah itu dilakukan perhitungan Six Big Losses yang dibagi menjadi Breakdown Losses, Setup and Adjustment Losses, Idling and Minor Stoppage Losses, Reduce Speed Losses, Process Defect Losses, dan Reduced Yield Losses. Pada tahap analisis dilakukan penguraian penyebab masalah menggunakan metode Failure Mode and Effect Analysis. Tahap terakhir yaitu penentuan rekomendasi perbaikan berdasar sistem penerapan pilar Total Productive Maintenance. Hasil perhitungan OEE menunjukkan bahwa nilai OEE pada mesin sebesar 33,19%, dimana nilai tersebut masih dibawah standar internasional yaitu sebesar 85%. Oleh karena itu dilakukan perhitungan Six Big Losses guna menemukan losses mana yang paling berpengaruh terhadap nilai efektivitas mesin. Ditemukan bahwa losses terbesar adalah Reduced Speed Losses dan Process Defect Losses yaitu dengan nilai persentase sebesar 42,63% dan 21%. Kemudian dilakukan analisis Failure Mode and Effect Analysis untuk menemukan jenis kegagalan pada jenis losses Reduced Speed Losses dan Process Defect Losses. Ditemukan dua jenis kegagalan paling dominan yaitu Cam dan Cam Lever yang mengalami keuasan serta Sliding Bearing yang mengalami hambatan. Diusulkan rekomendasi perbaikan menggunakan penerapan 4 pilar Total Productive Maintenance, yaitu pilar Autonomous Maintenance, Planned Maintenance, Quality Maintenance, dan Early Equipment Management.
English Abstract
The industrial sector is currently competing to improve technology and production systems to become more effective and efficient. When the company's production system can be effective and efficient it will have a positive impact both in terms of the quality of the products produced and production targets that are easy to achieve. PC Association of Indonesian Batik Cooperatives is a company that engaged in the textile sector, the ordering system of this company itself has two types, namely, make to stock and make to order. However, in the production process, there are still many defective products that are found due to the high downtime of the Air Jet Loom engine used in the production process. Therefore, it is necessary to identify the main causes of high downtime on the production machines used by using the Total Productive Maintenance method and provides recommendations for improvement to increase the effectiveness of the machine. In this study, the Total Productive Maintenance method used is OEE (Overall Equipment Effectiveness) where this method is used to calculate the effectiveness value of a machine and continues with the calculation of the largest losses using the Six Big Losses method. The OEE calculation phase begins with calculating the Availability Rate, Performance Rate, and Rate of Quality. The data needed is used to find the percentage value of OEE. After that, the Six Big Losses are calculated which are divided into Breakdown Losses, Setup and Adjustment Losses, Idling and Minor Stoppage Losses, Reduce Speed Losses, Process Defect Losses, and Reduced Yield Losses. At the analysis stage, the cause of the problem is described using the Failure Mode and Effects Analysis method. The last stage is determining improvement recommendations based on the Total Productive Maintenance pillar implementation system. The results of the OEE calculation show that the OEE value on the machine is 33.19%, where the value is still below the international standard of 85%. Therefore, the calculation of Six Big Losses is carried out to find which losses have the most influence on the machine's effectiveness value. It was found that the biggest losses were Reduced Speed Losses and Process Defect Losses with percentage values of 42.63% and 21%, respectively. Then, Failure Mode and Effect Analysis were performed to find the type of failure in the types of losses Reduced Speed Losses and Process Defect Losses. The two most dominant types of failure were found namely CAM and CAM Lever which experienced wear and tear and Sliding Bearing which experienced obstacles. Recommendations for improvement are proposed using the implementation of 4 pillars of Total Productive Maintenance, namely the pillars of Autonomous Maintenance, Planned Maintenance, Quality Maintenance, and Early Equipment Management.
Other obstract
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| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 0522070123 |
| Uncontrolled Keywords: | Kata Kunci: Total Productive Maintenance, OEE, Six Big Losses, Failure Mode and Effect Analysis |
| Subjects: | 600 Technology (Applied sciences) > 670 Manufacturing |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | yulia Chasanah |
| Date Deposited: | 27 Jul 2022 02:40 |
| Last Modified: | 27 Jul 2022 02:43 |
| URI: | http://repository.ub.ac.id/id/eprint/192767 |
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