ANALISIS PENGARUH SIX BIG LOSSES TERHADAP KINERJA MESIN LAS GMAW DI LEMBAGA PELATIHAN KERJA PEMERINTAH MENGGUNAKAN METODE SEM-PLS DAN FMEA

PAMENTA, MARKUS (2023) ANALISIS PENGARUH SIX BIG LOSSES TERHADAP KINERJA MESIN LAS GMAW DI LEMBAGA PELATIHAN KERJA PEMERINTAH MENGGUNAKAN METODE SEM-PLS DAN FMEA. S2 thesis, Universitas Mercu Buana Jakarta.

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Abstract

One of the important elements in the world of the manufacturing industry is maintaining optimal machine performance to increase company productivity. Measuring machine performance can be done by implementing Total Productive maintenance, evaluating Overall Equipment effectiveness, and identifying all losses that occur so that improvements can be made to eliminate them. The main components of the OEE evaluation are all six big loss indicators that have an impact on machine performance and productivity. One of the Training Institutes in Indonesia is located in the city of Serang, Banten, and conducts CompetencyBased Training in several vocational fields. One of the training areas is the welding engineering major. Training in welding techniques must be supported by machine performance, which is always in optimal condition. The occurrence of damage to the welding machine will cause decreased productivity and delays in training. This research was conducted to analyze all six big loss indicators that affect performance on Gas Metal Arc Welding (GMAW) machines using the SEM-PLS and FMEA methods. The calculation results show an OEE value of 60.27%, which is still low compared to world-class standards of 85%. Data processing using the SEM-PLS statistical method shows that there are five (five) big loss indicators that affect the low performance of the welding machine, namely breakdown losses (X11). Setup and Adjustment Losses (X12), Idling and Minor Stoppage Losses (X21), and Defect Losses (X31) Reduced yield losses (X32) The results of the FMEA analysis of the five losses show that there are three indicators that have the highest RPN values, namely Breakdown Losses (x11) and machine maintenance that is not carried out routinely, with an RPN value of 294. Setup and Adjustment Losses (x12) The welding current that is set does not match the output with an RPN value of 343 and defect losses (x31) welding results are not up to standard with an RPN value of 294. These three indicators are the top priority of all improvements that must be made to improve machine performance so that the performance of the welding machine can be optimal. From the results of the improvements made, an increase in the OEE value of 19.48% was obtained. Keywords: OEE, Six Big Losses, SEM-PLS and FMEA. Salah satu unsur penting dalam dunia industri manufaktur adalah menjaga kinerja mesin tetap optimal untuk meningkatkan produktivitas perusahaan. Mengukur kinerja mesin dapat dilakukan dengan penerapan Total Productive Maintenance dengan mengevaluasi Overall Equipment Effectiveness dan mengidentifikasi semua kerugian yang terjadi agar dapat dilakukan perbaikan untuk menghilangkannya. Komponen utama evaluasi OEE adalah semua indikator six big losses yang berdampak pada kinerja dan produktivitas mesin. Salah satu Lembaga Pelatihan di Indonesia yang terletak di kota Serang Banten yang melakukan Pelatihan Berbasis Kompetensi dengan beberapa bidang kejuruan. Salah satu bidang pelatihan dilaksanakan adalah jurusan teknik pengelasan. Pelatihan pada teknik Las harus didukung performa mesin yang selalu dalam kondisi yang optimal. Terjadinya kerusakan pada mesin las akan menyebabkan menurunnya produktivitas dan terhambatnya pelatihan. Penelitian ini dilakukan untuk menganalisis semua indikator six big losses yang mempengaruhi kinerja pada mesin las Gas Metal Arc Welding (GMAW) menggunakan metode SEMPLS dan FMEA Hasil perhitungan menunjukkan nilai OEE sebesar 60,27% masih rendah dibandingkan standar kelas dunia 85%. Dari pengolahan data menggunakan metode statistik SEM-PLS menunjukkan bahwa ada 5 (lima) indikator six big losses yang mempengaruhi rendahnya kinerja mesin las yaitu breakdown Losses (X11) Setup and Adjustment Losses (X12, Idling and Minor Stoppages Losses (X21) dan defect losses (X31) Reduced yield losses (X32). Hasil analisis FMEA dari kelima losses tersebut menunjukkan ada 3 indikator yang mempunyai nilai RPN tertinggi yaitu pada Breakdown Losses (x11) Pemeliharaan mesin tidak dilakukan secara rutin dengan nilai RPN 294. Setup and Adjustment Losses (x12) Arus pengelasan yang disetel tidak sesuai dengan keluaran dengan nilai RPN 343 dan defect losses (x31) hasil pengelasan belum sesuai standar dengan nilai RPN 294. Ketiga indikator tersebut menjadi prioritas utama dari semua perbaikan yang harus dilakukan untuk meningkatkan kinerja mesin agar performa mesin las dapat optimal. Dari hasil improvement yang dilakukan diperoleh peningkatan nilai OEE sebesar 19,48%. Kata kunci: OEE, Six Big Losses, SEM-PLS dan FMEA

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