ANALISIS OVERALL EQUIPMENT EFFECTIVENESS MESIN STAMPING DI INDONESIA DENGAN METODE DMAIC DAN SMED UNTUK MENINGKATKAN PRODUKTIVITAS

SUHENDRA, SUHENDRA (2021) ANALISIS OVERALL EQUIPMENT EFFECTIVENESS MESIN STAMPING DI INDONESIA DENGAN METODE DMAIC DAN SMED UNTUK MENINGKATKAN PRODUKTIVITAS. S2 thesis, Universitas Mercu Buana Jakarta.

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Abstract

Indonesian car sales, which dropped dramatically by 44% at the end of 2020 due to the impact of COVID-19 outbreak, make all domestic OEMs (Original Equipment Manufacturers) look for ways to survive and be able to carry out the production process. One way is to reduce losses in all production lines including the manufacturing process of components (parts) at all suppliers. The stamping process is the first process in car assembly and which is high cost process, because it is associated with purchasing raw material for steel, investing in machines and dies to make car bodies or components. Therefore, the effectiveness of stamping machine performance is very important to reduce these losses. Measuring machine performance using OEE (Overall Equipment Effectiveness) and six big losses is very effective in reducing waste or losses so that machine productivity can be increased. This study aims to determine the causative factors as well as increase the OEE value on the 800T stamping machine at PT XYZ, through DMAIC (Define, Measure, Analyze, Improve, and Control) methods as frame work and the SMED (Single Minutes Exchange of Dies) to reduce setup and adjustment losses. By this integration methods, dies change over time on the 800T stamping machine PT XYZ was decreased from 17.1 to 11.2 minutes. As the result, productivity and OEE value of that machine also increased from 62.4% to 78.2%. Keywords : Overall Equipment Effectiveness, DMAIC frame work, stamping, six big losses, Single Minute Exchange of Dies (SMED) Penjualan mobil Indonesia yang turun drastis hingga 44% pada akhir tahun 2020 akibat dampak wabah COVID-19 membuat seluruh OEM (Original Equipment Manufacturers) dalam negeri mencari cara untuk bertahan dan dapat menjalankan proses produksinya. Salah satu caranya adalah dengan mengurangi kerugian di semua lini produksi termasuk proses pembuatan komponen (suku cadang) di semua pemasok. Proses stamping merupakan proses pertama dalam perakitan mobil dan merupakan proses yang berbiaya tinggi, karena terkait dengan pembelian bahan baku baja, investasi mesin dan dies untuk membuat body atau komponen mobil. Oleh karena itu, efektifitas kinerja mesin stamping sangat penting untuk mengurangi kerugian tersebut. Pengukuran kinerja mesin menggunakan OEE (Overall Equipment Effectiveness) dan six big losses sangat efektif dalam mengurangi pemborosan atau kerugian sehingga produktivitas mesin dapat ditingkatkan. Penelitian ini bertujuan untuk mengetahui faktor penyebab serta meningkatkan nilai OEE pada mesin stamping 800T di PT XYZ, melalui metode DMAIC (Define, Measure, Analyze, Improvement, and Control) sebagai frame work dan SMED (Single Minutes Exchange of Dies) untuk mengurangi setup and adjustment losses. Dengan integrasi kedua metode ini, waktu setup (dies change over) pada mesin stamping 800T di PT XYZ menurun dari 17.1 menjadi 11.2 menit. Hal ini memberi dampak positif terhadap produktivitas sekaligus meningkatkan nilai OEE mesin stamping tersebut dari 62.4% menjadi 78.2%. Kata kunci : Overall Equipment Effectiveness, DMAIC frame work, stamping, six big losses, Single Minute Exchange of Dies (SMED)

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