PENINGKATKAN PRODUKTIVITAS PABRIK MELALUI MESIN CASTING DENGAN ANALISA CYCLE TIME MENGGUNAKAN METODE THEORITICAL VALUE PRODUCTION & PDCA

DS, MHD RAHMAN (2024) PENINGKATKAN PRODUKTIVITAS PABRIK MELALUI MESIN CASTING DENGAN ANALISA CYCLE TIME MENGGUNAKAN METODE THEORITICAL VALUE PRODUCTION & PDCA. S2 thesis, Universitas Mercu Buana - Menteng.

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Abstract

Penelitian dilakukan pada perusahaan pembuatan komponen automotif baik kendaraan roda dua dan roda empat yang dibuat berdasarkan bahan baku dari alumunium. Proses yang ada pada perusahaan tersebut adalah proses die casting, machining, assembly, & painting. Pada penelitian ini, penulis fokus untuk meneliti proses die casting. Nilai OEE pada bulan Mei, Juni & Juli tahun 2023 untuk mesin no. 2 sebesar 80.9% dan mesin no. 6 sebesar 80.2%. Hasil OEE ini tidak mencapai target yang ditentukan perusahaan yaitu 85% dan terhadap forecast di tahun 2024 tidak dapat terpenuhi. Penelitian ini mebahas bagaimana caranya produktivitas agar ouput dari proses die casting bertambah dan meningkatkan hasil OEE pada mesin no.2 dan no.6. Kemudian dilakukan klasifikasi pergerakan value, semi value dan non value dengan menggunakan theoritical value production (TVP) dan hasil diskusi dengan orang yang berpengalaman dibidangnya melalui focus group disscusion, didapatkan cycletime 40 detik dengan pergerakan value sebesar 9.95 detik, semi value sebesar 23.08 detik, dan non value sebesar 6.91 detik. Sedangkan untuk mesin no.6, nilai cycletime didapatkan adalah 37 detik dengan pergerakan value sebesar 7.99 detik, semi value sebesar 22.40 detik, dan non value sebesar 6.61 detik. Terhadap pergerakan non value dilakukan analisa PDCA melalui focus group disscusion. Hasil dari analisa PDCA memberikan ide improvement berdasarkan kategori perbaikan dengan eliminate, combine, re-arange, simplify (ECRS). Dari hasil simulasi perbaikan, didapatkan cycletime pada mesin no.2 berkurang sebesar 6.91 detik menjadi total 33.09 detik dengan produktifitas 1.45. Sedangkan untuk mesin no.6 berkurang sebesar 6.61 detik menjadi total 30.39 detik dengan produktifitas 1.38. Penelitian ini memberikan wawasan yang sangat berguna dan dapat diimplementasikan di semua mesin yang ada di dalam perusahaan. The research was conducted at an automotive component manufacturing company for both two-wheeled and four-wheeled vehicles made from aluminum raw materials. The processes in the company are die casting, machining, assembly, & painting. In this study, the author focused on examining the die casting process. The OEE value in May, June & July 2023 for machine no. 2 was 80.9% and machine no. 6 was 80.2%. The OEE results did not reach the company's target of 85% and the forecast for 2024 could not be met. This research discusses how to increase productivity so that the output from the die casting process increases and increases the OEE results on machines no. 2 and no. 6. Then the value, semi-value and non-value movements were classified using theoretical value production (TVP) and the results of discussions with experienced people in their fields through focus group discussions, obtained a cycle time of 40 seconds with a value movement of 9.95 seconds, semi-value of 23.08 seconds, and non value of 6.91 seconds. Meanwhile, for machine no. 6, the cycle time value obtained was 37 seconds with a movement value of 7.99 seconds, semi value of 22.40 seconds, and non value of 6.61 seconds. PDCA analysis was carried out on non-value movements through focus group discussions. The results of the PDCA analysis provide improvement ideas based on improvement categories with eliminate, combine, re-range, simplify (ECRS). From the results of the repair simulation, it was found that the cycle time on machine no. 2 was reduced by 6.91 seconds to a total of 33.09 seconds with a productivity of 1.45. Meanwhile, for machine no. 6, it decreased by 6.61 seconds to a total of 30.39 seconds with a productivity of 1.38. This research provides very useful insights and can be implemented on all machines in the company.

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