RAHMAN, DWI ARIF (2023) ANALISIS PRODUKTIVITAS MESIN INJECTION NOMER 5 DENGAN METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE) DAN ROOT CAUSE FAILURE ANALYSIS (RCFA) DI PT HINOMOTO INDONESIA. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
The manufacturing industry is required to be able to meet the needs and desires of customers such as good product quality, affordable prices, and production process time that is in line with the target. Maintenance or maintenance is an effort made by every company to keep machines or equipment in top condition. PT. Hinomoto Indonesia is a company that focuses on plastic and metal manufacturing. Production machine 5 has the highest downtime for three months with a total downtime of 3,510 minutes. Amounting to 2,400 minutes in January, 120 minutes in February and 990 minutes in March. The machine exceeded the company's downtime target of 780 minutes per month which resulted in a decrease in machine productivity so that it could have an impact on a low level of machine effectiveness. Thus, this study aims to determine the effectiveness value of 5 production machines based on the Overall Equipment Effectiveness (OEE) method in January - March 2022. Based on the Japan Institute of Plant Maintenance (JPIM), the world-class productivity standard is 85%. The OEE value of injection machines 5 in January - March 2022, namely, January is 50%, February is 81%, and March is 29%. Therefore, the effectiveness of injection 5 engines is still very far from world-class OEE standards. To get the cause of the low OEE value analyzed using six major losses. The value of the six major losses obtained is, 3.5% for damage losses, 1% for Setup & Adjustment Losses, 0% for Idling & Minor Stoppages Losses, 40.6% Reduced Speed Losses, 0.9% for Quality Defect Losses and 0.06% for Yield Losses. Based on the fishbone diagram approach and Root cause failure analysis (RCFA), suggestions for improvement are obtained for the company, namely conducting knowledge refresher, conducting briefings before carrying out the production process, and adding mainpower specifically tasked with ensuring and checking the condition of machines and tools ready for use in the production process. Keywords: machine effectiveness, overall equipment effectiveness, OEE, six big losses, root cause failure analysis, RCFA Industri manufaktur dituntut dapat memenuhi kebutuhan dan keinginan pelanggan seperti kualitas produk yang bagus, harga yang terjangkau, serta waktu proses produksi yang sesuai dengan target. Pemeliharaan atau maintenance merupakan upaya yang dilakukan setiap perusahaan untuk menjaga mesin atau peralatan dalam kondisi yang selalu prima. PT. Hinomoto Indonesia adalah perusahaan yang berfokus pada bidang manufaktur plastic dan metal. Mesin produksi 5 memiliki waktu downtime paling tinggi selama tiga bulan dengan total downtime 3.510 menit. Sebesar 2.400 menit pada bulan Januari, 120 menit pada bulan Februari dan 990 menit pada bulan Maret. Mesin tersebut melebihi target downtime perusahaan yaitu 780 menit setiap bulannya yang mengakibatkan menurunnya produktivitas mesin sehingga dapat berefek terhadap tingkat efektifitas mesin yang rendah. Sehingga, penelitian ini bertujuan untuk mengetahui nilai efektivitas mesin produksi 5 berdasarkan metode Overall Equipment Effectiveness (OEE) pada bulan Januari - Maret 2022. Berdasarkan Japan Institute of Plant Maintenance (JPIM), standar produktivitas kelas dunia sebesar 85%. Nilai OEE mesin injection 5 pada bulan Januari - Maret 2022 yaitu, Januari sebesar 50%, Februari sebesar 81%, dan Maret sebesar 29%. Maka dari itu, efektivitas mesin injection 5 masih sangat jauh dari standar OEE kelas dunia. Untuk mendapatkan penyebab rendahnya nilai OEE dianalisis menggunakan six big losses. Nilai dari six big losses yang didapatkan yaitu, 3,5% untuk breakdown losses, 1% untuk Setup & Adjustment Losses, 0% untuk Idling & Minor Stoppages Losses, 40,6% Reduced Speed Losses, 0,9% untuk Quality Defect Losses dan 0,06% untuk Yield Losses. Berdasarkan pendekatan fishbone diagram dan Root cause failure analysis (RCFA), didapatkan usulan perbaikan untuk perusahaan yaitu mengadakan knowledge refreshment, melakukan breafing sebelum melakukan proses produksi, dan menambah mainpower yang bertugas khusus untuk memastikan dan mengecek kondisi mesin dan alat siap digunakan dalam proses produksi. Kata Kunci: efektifitas mesin, overall equipment effectiveness, OEE, six big losses, root cause failure analysis, RCFA
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