PENERAPAN AUTONOMOUS MAINTENANCE PADA LINI PRODUKSI MESIN PERKAKAS UNTUK MENINGKATKAN NILAI OVERALL EQUIPMENT EFFECTIVENESS (OEE) DI BALAI YASA PT. KERETA API INDONESIA (DAOP 1)

KAHFI, MAUDY AZKHAIRIL (2019) PENERAPAN AUTONOMOUS MAINTENANCE PADA LINI PRODUKSI MESIN PERKAKAS UNTUK MENINGKATKAN NILAI OVERALL EQUIPMENT EFFECTIVENESS (OEE) DI BALAI YASA PT. KERETA API INDONESIA (DAOP 1). S1 thesis, Universitas Mercu Buana Jakarta.

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Abstract

Balai Yasa Manggarai is a train maintenance facility from PT. Kereta Api. Indonesia. Underfloor wheel lathe is one of the machine tools used to carry out the process of wheel set. But in the process damage often occurs that takes a lot of production downtime. For this reason, this research was conducted. Data are collected to calculate the Overall Equipment Effectiveness (OEE) on the underfloor lathe from April to October 2018. Then an OEE value analysis and six big losses analyzed by using Pareto chart to find indicators that affect the OEE value. To increase the OEE value, Autonomous Maintenance (AM) will be carried out by the operator on the underfloor lathe. After that the OEE value will be calculated to see the improvement made after the application of AM. The results of the calculation of OEE values in April-October 2018 obtained an average value of Availability Rate (Ar) of 77.59%, Performance Rate (Pr) of 81.21% and Quality Rate (Qr) had a value of 100% so that the average value was obtained The OEE underfloor lathe is 63.34%. This value is very low when compared with the OEE parameter which is a reference for worldclass companies. After doing the analysis, the biggest category of six big losses are Late Start / Early Stop and Breakdown Loss. Which is the top priority to look for the cause is the breakdown loss category. Brekdown Loss will be analyzed using cause and effect charting. As a step to repair the breakdown loss and an attempt to increase the OEE value, the AM will be applied by the operators on the underfloor lathe. After the implementation of AM, Ar is obtained at 86.90%, Pr at 95.16%, Qr at 100% and OEE increases to 82.69%. The results of the calculation of OEE values have not exceeded the reference of worldclass companies that have been set, which is 85%. But small damage can be minimized directly by the operators by carrying out AM actions. Keywords: production downtime, overall equipment effectiveness, autonomous maintenance, six big losses, pareto chart, cause and effect charting. Balai Yasa Manggarai merupakan sarana perawatan kereta dari PT. Kereta Api Indonesia. Mesin bubut roda underfloor adalah salah satu mesin perkakas yang digunakan untuk melakukan proses pembubutan roda (wheel set) kereta api. Namun pada prosesnya sering terjadi kerusakan-kerusakan yang memakan banyak downtime produksi. Untuk itulah penelitian ini dilakukan. Data dikumpulkan untuk menghitung nilai Overall Equipment Effectiveness (OEE) pada mesin bubut underfloor dari bulan April-Oktober 2018. Kemudian akan dilakukan analisa nilai OEE dan analisa six big losses dengan menggunakan diagram pareto untuk menemukan indikator yang mempengaruhi nilai OEE. Untuk meningkatkan nilai OEE akan dilakukan penerapan Autonomous Maintenance (AM) yang akan dilakukan operator pada mesin bubut underfloor. Setelah itu nilai OEE akan dihitung untuk melihat peningkatan yang dilakukan setelah penerapan AM. Hasil perhitungan nilai OEE pada bulan April-Oktober 2018 diperoleh ratarata nilai Availability Rate (Ar) sebesar 77,59%, Performance Rate (Pr) sebesar 81,21% dan Quality Rate (Qr) mempunyai nilai 100% sehingga didapatkan nilai rata-rata OEE mesin bubut underfloor adalah sebesar 63,34 %. Nilai ini sangat rendah bila dibandingkan dengan parameter OEE yang menjadi acuan perusahaan seluruh dunia (worldclass). Setelah dilakukannya analisa, kategori six big losses yang paling besar adalah Late Start/Early Stop dan Breakdown Loss. Yang menjadi prioritas utama untuk dicari penyebabnya adalah kategori breakdown loss. Brekdown Loss akan dianalisa menggunakan diagram sebab-akibat. Sebagai langkah perbaikan breakdown loss dan upaya untuk meningkatkan nilai OEE maka akan dilakukan penerapan AM oleh operator pada mesin bubut underfloor. Setelah dilakukannya penerapan AM maka diperoleh Ar sebesar 86,90%, Pr sebesar 95,16%, Qr sebesar 100% dan nilai OEE meningkat menjadi 82,69%. Hasil perhitungan nilai OEE memang belum melebihi acuan perusahaan diseluruh dunia (worldclass) yang sudah ditetapkan, yaitu 85%. Namun kerusakan–kerusakan kecil dapat diminimalisirkan langsung oleh operator dengan melakukan tindakantindakan AM. Kata kunci: downtime produksi, overall equipment effectiveness, autonomous maintenance, six big losses, diagram pareto, diagram sebab-akibat.

Item Type: Thesis (S1)
NIM: 41614120118
Uncontrolled Keywords: downtime produksi, overall equipment effectiveness, autonomous maintenance, six big losses, diagram pareto, diagram sebab-akibat.
Subjects: 000 Computer Science, Information and General Works/Ilmu Komputer, Informasi, dan Karya Umum > 020 Library and Information Sciences/Perpustakaan dan Ilmu Informasi > 025 Operations, Archives, Information Centers/Operasional Perpustakaan, Arsip dan Pusat Informasi, Pelayanan dan Pengelolaan Perpustakaan > 025.3 Bibliographic Analysis and Control/Bibliografi Analisis dan Kontrol Perpustakaan > 025.34 Cataloging, Classification, Indexing of Special Materials/Pengatalogan, Klasifikasi, Pengindeksan Bahan Tertentu > 025.344 Machine-Readable Materials/Bahan yang Dapat Dibaca Mesin
600 Technology/Teknologi > 620 Engineering and Applied Operations/Ilmu Teknik dan operasi Terapan
600 Technology/Teknologi > 620 Engineering and Applied Operations/Ilmu Teknik dan operasi Terapan > 621 Applied Physics/Fisika terapan
600 Technology/Teknologi > 620 Engineering and Applied Operations/Ilmu Teknik dan operasi Terapan > 621 Applied Physics/Fisika terapan > 621.8 Machine Engineering, Machinery/Teknik Mesin
600 Technology/Teknologi > 650 Management, Public Relations, Business and Auxiliary Service/Manajemen, Hubungan Masyarakat, Bisnis dan Ilmu yang Berkaitan > 653 Shorthand/Penulisan Cepat, Penulisan dengan Tangan > 653.3 Machine Systems/Sistem Mesin
Divisions: Fakultas Teknik > Teknik Industri
Depositing User: Dede Muksin Lubis
Date Deposited: 06 May 2019 02:46
Last Modified: 06 May 2019 02:46
URI: http://repository.mercubuana.ac.id/id/eprint/48692

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