Nugraha, Dhika Setya and Dr. Eng Oke Oktavianty,, S.Si., MT. (2023) Upaya Peningkatan Overall Equipment Effectiveness (OEE) Pada Proses Rolling Mill Dengan Pendekatan Single Minute Exchange of Dies (SMED). Sarjana thesis, Universitas Brawijaya.
Abstract
PT Jatim Taman Steel Plant 2 merupakan perusahaan manufaktur yang memproduksi flat bar dan round bar. Perusahaan memiliki masalah tekait downtime yang terbilang masih tinggi. Downtime ini dipengaruhi karena sering terjadinya penghentian mesin dikarenakan proses pergantian part mesin maupun kegagalan fungsi mesin ataupun pada hasil produksi yang menyebabkan kerugian yaitu mesin tidak berjalan dengan baik. Pada penelitian ini metode yang digunakan adalah Overall Equipment Effectiveness (OEE) dimana metode ini digunakan untuk menghitung nilai efektivitas dari suatu mesin dan dilanjutkan dengan menghitung losses terbesar menggunakan metode Six Big Losses. Tahap perhitungan OEE dimulai dengan melakukan perhitungan Availability Rate, Performance Rate, dan Quality Rate. Data tersebut dibutuhkan untuk menemukan nilai persentase OEE. Setelah itu dilakukan perhitungan Six Big Losses yang dibagi menjadi Breakdown Losses, Setup and Adjusment Losses, Idling and Minor Stoppage Losses, Reduce Speed Losses, Process Defect Losses, dan Reduced Yield Losses. Kemudian dilakukan analisis menggunakan Pareto dan Fishbone Diagram. Tahap terakhir yaitu penetuan rekomendasi perbaikan dengan metode Single Minute Exchange of Dies (SMED). Hasil perhitungan OEE menunjukkan bahwa nilai rata-rata OEE pada mesin Rolling Mill sebesar 45,74%, 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 Setup and Adjusment Losses dan Reduced Speed Losses yaitu dengan nilai persentase sebesar 49% dan 29%. Kemudian dilakukan analisis menggunakan Fishbone Diagram untuk menemukan penyebab utama dan mendapatkan solusi yang tepat terkait tingginya Setup and Adjusment Losses. Ditemukan dua faktor yang mempengaruhi yaitu belum ada evaluasi terhadap proses setup yang efisien dan belum ditetapkan standar instruksi kerja yang baku. Diusulkan rekomendasi perbaikan berupa analisis lebih lanjut mengenai penerapan metode Single Minute Exchange of Dies (SMED).
English Abstract
PT Jatim Taman Steel Plant 2 is a manufacturing company that produces flat bars and round bars. The company has problems related to downtime which is still relatively high. This downtime is affected due to the frequent occurrence of machine stoppages due to the process of changing machine parts or machine malfunctions or production results which cause losses, namely the machine is not running properly. In this study the method used is Overall Equipment Effectiveness (OEE) where this method is used to calculate the value of the effectiveness of a machine and is followed by calculating the largest losses using the Six Big Losses method. The OEE calculation phase begins by calculating the Availability Rate, Performance Rate, and Quality Rate. This data is needed to find the OEE percentage value. After that, the calculation of the Six Big Losses is carried out which is divided into Breakdown Losses, Setup and Adjustment Losses, Idling and Minor Stoppage Losses, Reduced Speed Losses, Process Defect Losses, and Reduced Yield Losses. Then do the analysis using Pareto and Fishbone Diagrams. The final stage is determining recommendations for improvement using the Single Minute Exchange of Dies (SMED) method. The OEE calculation results show that the OEE value on the machine is 45,74%, which is still below the international standard of 85%. Therefore, the calculation of Six Big Losses is carried out in order to find out which losses have the most influence on the value of machine effectiveness. It was found that the biggest losses were Setup and Adjustment Losses and Reduced Speed Losses with percentage values of 49% and 29%. Then an analysis was carried out using a Fishbone Diagram to find the main causes and get the right solution regarding the high Setup and Adjustment Losses. Two influencing factors were found, namely there was no evaluation of an efficient setup process and no standard work instructions had been established. Proposed recommendations for improvement in the form of further analysis regarding the application of the Single Minute Exchange of Dies (SMED) method.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 0523070028 |
| Uncontrolled Keywords: | Maintenance, Overall Equipment Effectiveness (OEE), Six Big Losses, Pareto Diagram, Fishbone Diagram, Single Minute Exchange of Dies (SMED). |
| Subjects: | 600 Technology (Applied sciences) > 670 Manufacturing |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Endang Susworini |
| Date Deposited: | 06 Jun 2023 07:18 |
| Last Modified: | 06 Jun 2023 07:18 |
| URI: | http://repository.ub.ac.id/id/eprint/200926 |
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