ANALISIS SIX BIG LOSSES TERHADAP PENINGKATAN OVERALL EQUIPMENT EFFECTIVENESS (OEE) PADA MESIN HYDRO TESTING

UTOMO, UTOMO (2021) ANALISIS SIX BIG LOSSES TERHADAP PENINGKATAN OVERALL EQUIPMENT EFFECTIVENESS (OEE) PADA MESIN HYDRO TESTING. S2 thesis, Universitas Mercu Buana Jakarta.

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Abstract

viii ABSTRACT Overall Equipment Effectiveness (OEE) is developed from the basis of Total Productive Maintenance (TPM) where OEE is a benchmark for measuring the performance of a machine or equipment. The value of OEE in valve manufacturing, testing is an important step to validate a design with hydro testing. The factors that affect the Overall Equipment Effectiveness (OEE) value are availability, performance efficiency, and quality level. Studies around the world show that the average OEE level in a company is 50% (Stamatis, 2017). World Class OEE around 85% or more with a score factor: 90.0% availability, 95.0% performance, and 99.9% quality rating. This research is based on measuring the performance of the hydrotest equipment through the achievement of Overall Equipment Effectiveness (OEE) compared to the world-class OEE standards. Where the OEE target that has been set by the company is 45%, while the current machine performance is around 27.0%. So it is necessary to increase performance by eliminating the variable six big losses in order to meet the expected performance targets. Speed losses consisting of idling and minor stoppage and reduced speed are the dominant factors affecting the overall equipment effectiveness (OEE) value of the hydrotest machine. Improvements made in this study are eliminating the factors that cause idling and minor stoppage based on the evaluation results with several tools used, namely Pareto diagrams, fishbone diagrams, 5 why analysis and FMEA. The root cause of addling and minor stoppage is due to the fact that periodic maintenance has not been implemented as part of the Total Productive Maintenance (TPM) program. The results of this corrective measure were able to increase the OEE value from 27.0% to 33.5%. This means that there is an increase in the OEE value by 6.5%. Keyword: overall equipment effectiveness (OEE), performance, hydrotest, six big losses vii ABSTRAK Overall Equipment Effectiveness (OEE) dikembangkan dari basis Total Productive Maintenance (TPM) dimana OEE merupakan tolak ukur untuk mengukur kinerja suatu mesin atau peralatan. Nilai OEE dalam pembuatan katup, pengujian adalah langkah penting untuk memvalidasi desain dengan pengujian hydrotest. Faktorfaktor yang mempengaruhi nilai Overall Equipment Effectiveness (OEE) adalah ketersediaan, efisiensi kinerja, dan tingkat kualitas. Studi di seluruh dunia menunjukkan bahwa rata-rata tingkat OEE di suatu perusahaan adalah 50% (Stamatis, 2017). OEE World Class Manufacturing adalah 85% atau lebih dengan faktor nilai: availability 90,0%, performance rate 95,0%, dan quality rate 99,9%. Penelitian ini didasarkan pada pengukuran kinerja peralatan hydrotest melalui pencapaian Overall Equipment Effectiveness (OEE) dibandingkan dengan standar World Class Manufacturing. Dimana target OEE yang telah ditetapkan oleh perusahaan sebesar 45%, sedangkan kinerja mesin saat ini berkisar 27,0%. Sehingga diperlukan peningkatan kinerja dengan cara menghilangkan variable six big losses guna memenuhi target kinerja yang diharapkan. Speed losses yang terdiri dari idling & minor stoppage serta reduced speed menjadi faktor dominan yang mempengaruhi nilai overall equipment effectiveness (OEE) mesin hydrotest tersebut. Perbaikan yang dilakukan dalam penelitian ini adalah menghilangkan faktor penyebab terjadinya idling & minor stoppage berdasarkan hasil evaluasi dengan beberapa quality tools yang digunakan yaitu pareto diagram, fishbone diagram, 5 why analysis serta Failure Mode Effect Analysis (FMEA). Root cause dari terjadinya iddling dan minor stoppage dikarenakan belum diterapkannya periodic maintenance sebagai bagian dari program Total Productive Maintenance (TPM). Hasil dari langkah perbaikan ini mampu menaikkan nilai OEE dari 27.0% menjadi 33.5%. Artinya terjadi kenaikan nilai OEE sebesar 6.5%. Kata kunci: overall equipment effectiveness (OEE), performance, hydrotest, six big losses

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