ANALISA PERBAIKAN BREAKDOWN REAKTOR RESIN DENGAN PENDEKATAN METODE OVERALL EQUIPMENT EFFECTIVENESS (STUDI KASUS PT. KANSAI PRAKARSA COATINGS)

JULIANTO, LINGGA WISNU (2023) ANALISA PERBAIKAN BREAKDOWN REAKTOR RESIN DENGAN PENDEKATAN METODE OVERALL EQUIPMENT EFFECTIVENESS (STUDI KASUS PT. KANSAI PRAKARSA COATINGS). S2 thesis, Universitas Mercu Buana-Menteng.

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Abstract

Dalam industri manufaktur, pengukuran terhadap kinerja peralatan produksi biasanya menggunakan pendekatan Overall Equipment Effectiveness (OEE). Reaktor resin PT. Kansai Prakarsa Coatings sering mengalami kerusakan atau kendala dimana performance pemeliharaan yang diukur dengan availability mendapatkan angka yang rendah dan tentunya menjadi tantangan tersendiri untuk melakukan upaya-upaya perbaikan melalui perhitungan OEE dan analisis six big losses. Tujuan penelitian ini adalah untuk mengoptimasi kinerja mesin reaktor melalui penerapan pengukuran overall equipment effectiveness (OEE) dan analisis six big losses. Penelitian ini merupakan penelitian deskriptif-kuantitatif dilakukan dengan mempelajari laporan harian produksi dan pemeliharaan, melakukan obervasi, wawancara dan focus discussion group (FGD). Penyebab masalah dianalisis dengan fishbone diagram sedangkan penyebab dominan (sebagai usulan untuk perbaikan) ditentukan berdasarkan Risk Priority Number (RPN) pada Failure Mode and Effect Analysis (FMEA). Berdasarkan hasil perhitungan data periode Januari-Desember 2016 yang dilakukan meliputi availability, performace rate dan quality rate telah didapatkan faktor dominan penyebab rendahnya OEE adalah reduced speed losses dan breakdown losses. Setelah dilakukan analisa yang ada melalui diagram fishbone maka dirumuskan sejumlah perbaikan melalui 5W+1H yang hasilnya adanya penurunan reduced speed losses 0,22% dan breakdown losses 5,87%. Dari 9 unit reaktor resin ada 2 unit yang memiliki nilai OEE rendah. Upaya yang dilakukan untuk perbaikan nilai OEE adalah dengan penerapan TPM: melaksanakan autonomous maintenance, penerapan 5W1H: membuat ide-ide kreatif dengan cara brainstorming atau menggali ide pemecahan masalah. Setelah penerapan ide perbaikan dilakukan, nilai simulasi yang diperoleh cukup baik, terjadi kenaikan dibandingkan dengan nilai OEE sebelum perbaikan Kata kunci: Availability, reduced speed losses, breakdown losses, OEE, TPM, 5W1H In the manufacturing industry, measurement of the performance of production equipment usually uses the Overall Equipment Effectiveness (OEE) approach. PT. Kansai Prakarsa Coatings have Resin reactor often experienced damage or constraints where maintenance performance measured by availability gets a low number and of course it becomes a challenge to make improvements through OEE calculations and six big losses analysis. The purpose of this study is to optimize the performance of reactor engines through the application of overall equipment effectiveness (OEE) measurements and analysis of six big losses. This research is a descriptive-quantitative study conducted by studying daily reports on production and maintenance, conducting observations, interviews and focus discussion groups (FGD). The cause of the problem is analyzed by fishbone diagram while the dominant cause (as a proposal for improvement) is determined based on the Risk Priority Number (RPN) in Failure Mode and Effect Analysis (FMEA). Based on the results of the January-December 2016 data calculation conducted including availability, performance rate and quality rate, the dominant factor causing low OEE is reduced speed losses and breakdown losses. After the analysis is done through a fishbone diagram, a number of improvements are formulated through 5W + 1H which results in a decrease in reduced speed losses of 0.22% and breakdown of losses of 5.87%. Of the 9 resin reactor units there are 2 units that have low OEE values. The efforts made to improve OEE values are by implementing TPM: implementing autonomous maintenance, implemented 5W1H: creating creative ideas by brainstorming or exploring problem solving ideas. After the implementation of the repair idea is done, the simulation value obtained is quite good, there is an increase compared to the OEE value before repair Keyword: Availability, reduced speed losses, breakdown losses, OEE, TPM, 5W1H

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