Usulan Perbaikan Sistem Kontrol Mesin dan Proses Produksi Polyurethane Foam Menggunakan Metode Failure Mode and Effect Analysis

HARIANDJA, AL AFIEF PINARDITAMA (2021) Usulan Perbaikan Sistem Kontrol Mesin dan Proses Produksi Polyurethane Foam Menggunakan Metode Failure Mode and Effect Analysis. S2 thesis, Universitas Mercu Buana Jakarta.

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Abstract

PT. Inoac Polytechno Indonesia, Tangerang and Karawang are the largest polyurethane foam factories in Indonesia with a total capacity of more than 2000 tons per month which produces foams of various specifications and different shapes. Mapping of problems is carried out in relation to total defects and the number of customer claims in order to get good production cost efficiency and good customer service, which is the initial stage of the process of defining the problem and to be followed up on future improvements. This research was conducted to solve problems related to the proposed process improvement in the production of Polyurethane Foam using the Failure Mode and Effect Analysis method. This is because the foam (Polyurethane) production process requires precision and precision in machine settings and process control because the foam production is completely based on chemical reaction conditions. From the results of observations, discussions and team agreements, there are three parts in production that have the opportunity to produce production failures or defects, namely material preparation, machine setting, production process. From the three processes above, the problem solving stage is carried out by analyzing the problem by using discussion, brainstorming, fishbone and FMEA together with the team. From the results of the analysis, it is found the sources of the possibility of defects and efforts to reduce defects. For the results of the agreement with the production, QC, R&D and Maintenance teams can be seen on the FME table. After obtaining the results of the analysis through PFMEA, the team began to prioritize improvements based on the RPR value obtained. Repairs are also determined according to the responsibilities of the relevant departments relating to problems that occur such as repair and maintenance of machines by the maintenance department, use of correct and good machines by the production department, material and formula control by the R&D department and product Quality Control by the QC department. Keywords: polyurthane, FMEA, Failure Mode and Effect Analysis, defect PT. Inoac Polytechno Indonesia, Tangerang dan karawang adalah pabrik polyurethane foam terbesar di Indonesia dengan kapasitas total lebih dari 2000 ton per bulan yang memproduksi busa dengan berbagai spesifikasi dan bentuk yang berbeda-beda. Pemetaan permasalahan dilakukan terkait dengan total cacat dan banyaknya komplain pelanggan untuk mendapatkan efisiensi biaya produksi dan pelayanan pelanggan yang baik, yang merupakan tahap awal dari proses define masalah dan untuk di tindak lanjuti improvement kedepannya. Penelitian ini dilakukan untuk memecahkan masalah terkait usulan perbaikan proses dalam pelaksanaan produksi Polyurethane Foam menggunakan metode Failure Mode and Effect Analysis. Dikarenakan proses produksi busa (Polyurethane) membutuhkan ketelitian dan ketepatan pengaturan mesin dan kontrol proses dikarenakan hasil produksi busa sepenuhnya berdasarkan pada kondisi reaksi kimia. Dari hasil pengamatan, diskusi dan kesepakatan team terdapat tiga bagian di produksi yang memiliki peluang untuk menghasilkan kegagalan produksi atau defect yaitu prepare material, setting mechine, proses produksi. Dari tiga proses di atas untuk tahapan penyelesaian masalah dilalukan Analisa masalah dengan menggunakan cara diskusi, brainstorming, fishbone dan FMEA bersama dengan team. Dari hasil Analisa di dapatkan sumber-sumber kemungkinan terjadinya cacat dan usaha untuk menurunkan cacat. Untuk hasil kesepakatan bersama team produksi, QC, R&D dan Maintenance dapat dilihat pada tabel FMEA. Setelah di dapat hasil dari analisa melalui PFMEA, team mulai melakukan prioritas perbaikan berdasarkan nilai RPN yang di dapat. Perbaikan di tentukan juga sesuai tanggung jawab departemen terkait yang berhubungan dengan masalah yang terjadi seperti perbaikan dan perawatan mesin oleh maintenance departemen, penggunaan mesin yang benar dan baik oleh departemen produksi, kontrol material dan formula oleh departemen R&D dan Quality Control product oleh departemen QC. Kata Kunci : polyurthane, FMEA, Failure Mode and Effect Analysis, defect

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