EVALUASI PENERAPAN TPM (TOTAL PRODUCTIVE MAINTENANCE) PADA MESIN DORNIER 2706 DENGAN METODE OEE (OVERALL EQUIPMENT EFFECTIVENESS) DI PT. MANUFAKTUR KAIN BAN

Rahmat, Abdul (2019) EVALUASI PENERAPAN TPM (TOTAL PRODUCTIVE MAINTENANCE) PADA MESIN DORNIER 2706 DENGAN METODE OEE (OVERALL EQUIPMENT EFFECTIVENESS) DI PT. MANUFAKTUR KAIN BAN. S1 thesis, Universitas Mercu Buana Bekasi.

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Abstract

Industri pembuatan bahan dasar penguat ban yang semakin meningkat di Indonesia, menyebabkan tingkat persaingan antara perusahaan menjadi semakin ketat. PT. Manufaktur Kain Ban adalah perusahaan asal Turki yang bergerak dibidang pembuatan kain ban (Tire Cord Fabric), memiliki beberapa alat/mesin yang membutuhkan reliability dengan target penggunaan zero failure. Perusahaan ini sudah menerapkan beberapa pilar TPM, tetapi program yang dilakukan ini tidak sejalan dengan tingginya kejadian failures atau defects yang terjadi pada divisi weaving yang umumnya terjadi pada Mesin Dornier 2706. Mesin/peralatan yang digunakan perlu di jaga kondisinya agar terhindar dari kerusakan. TPM (Total Productive Maintenance) merupakan suatu aktivitas kegiatan yang mengikut sertakan semua elemen dari perusahaan, yang bertujuan untuk menciptakan suasana kritis (critical mass) dalam lingkungan industri guna mencapai zero breakdown, zero defect dan zero accident untuk memaksimalkan effisiensi penggunaan peralatan dan memantapkan sistem perawatan preventif yang dirancang untuk keseluruhan peralatan. Tujuan penelitian ini ialah untuk mengetahui dan mempelajari potensi serta penyebab-penyebab kegagalan dari Mesin Dornier 2706 dan mencari Six Big Losses terbesar untuk kemudian hasil dari pengolahan data ini dianalisa dengan pareto diagram dan fishbone diagram guna mencari usulan perbaikan. Salah satu metode mengukur tingkat keberhasilan penerapan TPM adalah melalui pengukuran nilai OEE (Overall Equipment Effectiveness) Permasalahan yang terjadi pada perusahaan ini ialah berdasarkan history penerapan TPM dari awal bulan Mei 2018 sampai bulan Oktober 2018 nilai OEE pada Mesin Dornier 2706 masih rendah. Sehingga hasil produksi tidak sesuai pencapaian target perusahaan. Data dikumpulkan langsung dilapangan selama 24 minggu (6 bulan). Perhitungan nilai OEE diikuti dengan analisa Six Big Losses serta dianalisa dengan menggunakan Pareto Diagram dan fishbone diagram guna mencari usulan perbaikan. Berdasarkan hasil penelitian yang dilakukan dari pengolahan data diperoleh nilai OEE tertinggi yaitu terdapat pada periode minggu ke-6 dengan persentase sebesar 69.26%, sedangkan nilai OEE terendah terdapat pada periode minggu ke-9 yaitu sebesar 45.25% dengan OEE rata-rata 56.00%. Faktor six big losses yang paling berpengaruh terhadap rendahnya OEE Mesin Dornier 2706, diketahui dengan analisa Pareto Diagram, Fishbone Diagram adalah Breakdown loss dengan nilai 2.594 menit. Kata kunci: TPM (Total Productive Maintenance), OEE (Overall Equipment Effectiveness), Six Big Losses, Pareto Chart, Fishbone Diagram. Manufacture of basic materials the amplifier Tires increasing in Indonesia country, so that the level of competition between companies is becoming increasingly tight. Tire Cord Fabric Manufacturing Company is an origin Turkish company that specialize in Tire Cord Fabric. Have some of the tools/machines that need reliability with the target usage of zero failure. The company has already implemented some of the pillars of TPM, however this was not done program in line with the high incidence of failures or defects that occur in the weaving that generally occur on Dornier Machine 2706. Machines/tools used need to be guarded her condition to avoid damage. TPM (Total Productive Maintenance) is an activity of the activities requiring all elements of the company, which aims to create an atmosphere of critical (critical mass) in the environmental industry to achieve zero breakdown, zero defect zero accident and to maximize the efficiency of the use of the equipment and establish preventive care system designed for the whole equipment. The purpose of this research is to know and study the potential as well as the causes of the failure of the Dornier Machine 2706 and find Six Big Losses for the biggest result of the processing of data is analyzed with Pareto diagrams and fishbone diagram to seek proposals for improvement. One method of measuring the level of success of the application of the TPM is through the measurement of the value of OEE (Overall Equipment Effectiveness) problem happens to this company is based on the application of the TPM from the beginning of history on May 2018 to the October 2018 OEE values on the Dornier Machine 2706 is still low. So, the results of production do not match the achievement of the goal company. The data is collected directly in field for 24 weeks (6 months). Calculation of the OEE value has been followed by an analysis of the Six Big Losses as well as analyzed by fishbone diagrams and Pareto Diagram to finding the improvements proposed. Based on the results of research that conducted from processing of data obtained the highest value of OEE namely in the 6th week period with percentage of 69.26%, while the value of OEE lowest contained on the 9th week period i.e. of 45.25% with OEE 56.00% average. The six big losses factors most influential about the low OEE of Dornier Machine 2706, known by Pareto analysis and Fishbone Diagram are Breakdown loss which reach about 2,594 hours. Keywords: TPM (Total Productive Maintenance), OEE (Overall Equipment Effectiveness), Six Big Losses, Pareto Chart, Fishbone Diagram.

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