MAULANA, BAYU FIRMAN (2025) RANCANG BANGUN SISTEM KONTROL CONVEYOR FEEDING BERBASIS PLC MITSUBISHI PADA MESIN SIDEWALL. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
PT EFG manufactures Passenger Car Radial tires through key processes such as mixing, material preparation, building, curing, and final inspection. During the material stage, sidewalls are produced using a sidewall extruder machine that relies on three types of compounds fed through conveyor feeding. Conveyors are crucial for production efficiency but often encounter issues such as operational failures or control errors, resulting in significant downtime, recorded at 43 occurrences totaling 51.21 hours from June to August 2024. These problems stem from damaged motors, sensors, or outdated conventional control components. To resolve this, a new control system based on Mitsubishi Electric Programmable Logic Controller (PLC) is needed for increased reliability and ease of maintenance, which will help reduce downtime and enhance production efficiency. The research methodology employed involved field observations, literature studies, and analysis. The analysis was conducted using the Mean Time Between Failure (MTBF), which represents the average time a machine operates normally before experiencing a failure; the Mean Time To Repair (MTTR), which indicates the average time required for technicians to repair a machine; and Availability, which is the ratio of actual operating time of a machine to the total time it is expected to operate. The purpose of these analytical methods is to compare the downtime values before and after the research was conducted. The design of the control system for the upper, middle, and lower feeding conveyors at PT EFG has successfully transitioned from a conventional system using DC motors to a system based on Mitsubishi PLC and AC motors with VFD inverters. This change has increased the average time for the machine to resume operation after a failure to 88.47 hours. The implementation of ladder logic programming in the PLC, utilizing various input and output instructions, has enabled more efficient control, reducing the repair time by technicians to 1.53 hours. Following the redesign, downtime for the sidewall machine showed significant improvement, with the Mean Time Between Failures (MTBF) increasing from 43.78 hours to 88.47 hours, while the Mean Time To Repair (MTTR) rose from 1.219 hours to 1.53 hours. Additionally, availability improved from 97.29% to 98.3%, although it still falls short of the target machine availability of 99%. These changes reflect a qualitative and quantitative enhancement in system performance. Keywords: Availability; Conveyor; Downtime; Ladder; MTBF; MTTR; PLC PT EFG memproduksi ban Passenger Car Radial dengan proses utama seperti mixing, material, building, curing, dan final inspection. Pada tahap material, sidewall dibuat menggunakan mesin sidewall extruder yang mengandalkan tiga jenis compound melalui conveyor feeding. Conveyor berperan penting dalam efisiensi produksi, namun sering mengalami masalah seperti tidak beroperasi atau kesalahan pengendalian, yang menyebabkan downtime tinggi, tercatat 43 kali dengan total 51,21 jam selama Juni–Agustus 2024. Masalah ini disebabkan oleh kerusakan motor, sensor, atau komponen kontrol konvensional yang sudah usang. Untuk mengatasinya, diperlukan sistem kontrol baru berbasis Programmable Logic Controller (PLC) Mitsubishi Electric yang lebih andal dan mudah diperbaiki, sehingga dapat mengurangi downtime dan meningkatkan efisiensi produksi. Metode penelitian yang dilakukan yaitu dengan observasi lapangan dan studi literatur, serta analisis. Analisis dibuat dengan metode (MTBF) Mean Time Between Failure yang merupakan rata-rata waktu suatu mesin yang dapat berjalan normal sampai mengalami kerusakan, (MTTR) Mean Time To Repair yang merupakan rata-rata waktu yang diperlukan teknisi untuk memperbaiki suatu mesin, dan Availability yang merupakan perbandingan waktu yang sebenarnya untuk suatu mesin beroperasi dengan waktu yang telah ditetapkan harus beroperasi. Analisis metode tersebut bertujuan untuk membandingkan nilai downtime sebelum dan sesudah penelitian. Perancangan sistem kontrol untuk conveyor feeding upper, middle, dan lower di PT EFG telah berhasil diubah dari sistem konvensional dengan motor DC menjadi sistem berbasis PLC Mitsubishi dan motor AC menggunakan Inverter VFD, yang meningkatkan rata-rata waktu mesin kembali beroperasi setelah kerusakan menjadi 88,47 jam. Implementasi ladder PLC dengan berbagai instruksi input dan output memungkinkan pengendalian yang lebih efisien, sehingga waktu perbaikan oleh teknisi berkurang menjadi 1,53 jam. Setelah perancangan, downtime pada mesin sidewall menunjukkan perbaikan signifikan yaitu nilai Mean Time Between Failures (MTBF) meningkat dari 43,78 jam menjadi 88,47 jam, sementara Mean Time To Repair (MTTR) meningkat dari 1,219 jam menjadi 1,53 jam. Nilai availability juga mengalami peningkatan dari 97,29% menjadi 98,3%, meskipun masih belum mencapai target availability mesin sebesar 99%. Perubahan ini mencerminkan peningkatan kinerja sistem secara kualitatif dan kuantitatif. Kata kunci: Availability; Conveyor; Downtime; Ladder; MTBF; MTTR; PLC
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