ROSITA, JAENUDIN ANGGA (2019) ANALISIS DAN PERBAIKAN GEMBA KAIZEN DENGAN MENGGUNAKAN METODE FMEA DI DEPARTEMEN WELDING PT. XYZ TANGERANG. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
Kaizen team welding department at PT.XYZ in the early stages of the program the initial phase has been carried out improvements in the WIP process has not yet had a maximum impact on achieving its production planning targets, seen from the performance report data before and after the improvement shows inconsistent planning achievement, the target of 98% but the actual is still below 90%. Therefore the kaizen welding department team must immediately conduct an evaluation and improvement of the ongoing production process. The method used in this research is the Failure Mode and Effects Analysis (FMEA) method to identify and analyze failures that occur during the production process. The purpose of this study is to analyze the factors that cause the failure of the production process in achieving planning targets. After an annealing is done, there are two types of failures that must be repaired directly by the welding department, namely in the production process of plate comp pivot with types of failure B2 (Wait for Process) and B1 (Robot is the maximum), and there are 4 failure modes that occur and refer to the 3 highest RPN values that are interrelated and need to be repaired, then the improvement efforts made by the welding department's kaizen team are by: Move 3 brushing machines, 1 manual welding machine, 2 K15G and K45G checking / packing tables to the side of the special robot welding plate comp pivot process, and a good finish area to the side of the raw material area. Position 1 table to be brought to the side of the welding machine R.21, R.23, R.25, R.27 specifically for the production of K45G plate type pivot comp, and 1 table for the close side of the welding machine R.22, R.24 , R.26, R.28 specifically the K15G type plate comp pivot production, and bringing the K15G and K45G chechking / packing tables. Making a conveyor roller with 2 support stages, in general the length of step-1 size is 380 cm slope 450, stage-2 280cm slope 450, and for the height measuring 160 cm, the distance of stage-1 to stage-2 40cm, while for the width size is 60 cm. After making improvements, the welding performance report data shows the percentage and graph are increasing and consistently above 90%. Keywords: Planning targets, Plate comp pivot, Failure mode and effects analysis (FMEA), risk priority number (RPN). Tim kaizen welding department PT. XYZ dalam program tahap awal yang sudah dilakukan perbaikan pada proses WIP belum berdampak maksimal terhadap pencapaian target planning produksinya, dilihat dari data performance report sebelum dan sesudah dilakukanya perbaikan menunjukan tidak konsistenya pencapaian planning, yang targetnya 98% tetapi aktualnya masih berada dibawah 90%. Oleh karena itu tim kaizen welding department harus segera melakukan evaluasi dan perbaikan terhadap proses produksi yang berlangsung. Metode yang digunakan dalam penelitian ini adalah metode Failure Mode and Effects Analysis (FMEA) untuk mengidentifikasi dan menganalisa kegagalan yang terjadi selama proses produksi. Tujuan penelitian ini adalah menganalisa faktor-faktor penyebab kegagalan proses produksi dalam pencapaian target planning. Setelah dilakukan anilasa maka terdapat dau jenis kegagalan yang harus di perbaiki langsung oleh departemen welding yaitu pada proses produksi plate comp pivot dengan jenis kegagalan B2 (Tunggu Proses) dan B1 (Robot Sudah Maksimal), serta ada 4 mode kegagalan yang terjadi dan mengacu terhadap 3 nilai RPN tertinggi yang saling berkaitan dan perlu dilakukan perbaikan, maka upaya perbaikan yang dilakukan oleh tim kaizen departemen welding adalah dengan: Memindahkan 3 mesin brushing, 1 mesin las manual, 2 meja checking/packing K15G dan K45G ke samping robot welding khusus proses plate comp pivot, dan area finish good jadi ke samping area raw material. Posisi 1 meja untuk di dekatkan ke samping mesin welding R.21, R.23, R.25, R.27 khusus produksi plate comp pivot tipe K45G, dan 1 meja untuk di dekatkan ke samping mesin welding R.22, R.24, R.26, R.28 khusus produksi plate comp pivot tipe K15G, dan mendekatkan meja chechking/packing K15G dan K45G. Membuat roller conveyor dengan 2 tahap penyanggaan, secara general untuk panjang ukuran tahap-1 adalah 380 cm kemiringan 450, tahap-2 280cm kemiringan 450, dan untuk tinggi ukuranya 160 cm, jarak tahap-1 ke tahap-2 40cm, sedangkan untuk ukuran lebarnya adalah 60 cm. Setelah dilakukan perbaikan maka data performance report welding menunjukan persentase dan grafik meningkat dan konsisten diatas angka 90%. Kata Kunci: Target planning, Plate comp pivot, Failure mode and effects analysis (FMEA), risk priority number (RPN).
| Item Type: | Thesis (S1) |
|---|---|
| Call Number CD: | FT/IND. 19 305 |
| Call Number: | ST/16/20/003 |
| NIM/NIDN Creators: | 41615120069 |
| Uncontrolled Keywords: | Target planning, Plate comp pivot, Failure mode and effects analysis (FMEA), risk priority number (RPN). |
| Subjects: | 500 Natural Science and Mathematics/Ilmu-ilmu Alam dan Matematika > 510 Mathematics/Matematika > 518 Numerical Analysis/Analisis Numerik, Analisa Numerik 500 Natural Science and Mathematics/Ilmu-ilmu Alam dan Matematika > 540 Chemistry/Kimia 600 Technology/Teknologi > 650 Management, Public Relations, Business and Auxiliary Service/Manajemen, Hubungan Masyarakat, Bisnis dan Ilmu yang Berkaitan |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | ELMO ALHAFIIDH PUTRATAMA |
| Date Deposited: | 24 Mar 2023 02:44 |
| Last Modified: | 24 Mar 2023 02:44 |
| URI: | http://repository.mercubuana.ac.id/id/eprint/75381 |
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