SANDIKA, FARHAN KAMIL (2019) ANALISIS PENYEBAB CACAT PRODUK PADA PROSES PENGELASAN FRAME MOBIL P6 ATAV MENGGUNAKAN METODE FAILURE MODE AND EFFECT ANALYSIS (FMEA) DI PT. SENTRA SURYA EKAJAYA. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
PT. Sentra Surya Ekajaya (PT. SSE) is one of the companies in Indonesia which is specialized in the design, engineering and manufacturing sector that produces military-specific vehicles. Based on field observations, it can still be found that there is an unavoidable defect where the quality of the P6 ATAV frame produced in the welding process is not in accordance with the quality standards set by the company which is 2% or 5 joints per unit. Therefore this study aims to analyze the types and causes of defects, as well as provide suggestions for improvements to reduce and prevent defects in the P6 ATAV frame product. The method used in this study is the Failure Mode and Effect Analysis (FMEA) method with the help of pareto diagram tools, fishbone diagrams, and 5W + 1H. The final result of the FMEA method is the Risk Priority Number (RPN) value obtained by multiplying severity, occurrence, and detection. Based on the results of the study, there are 3 highest RPN values, namely incomplete welding defects caused by Fatigue Operators (RPN = 315), Less Wide Lasers Swing Movement (RPN = 315), and No Standard Welding sequence (RPN = 270). For 5 other causes of failure, namely lack of standard knowledge of welding parameters, connection angle is too narrow, error in the bending / cutting process at the supplier, there is damage in the nozzle cable, the operator often changes. The proposal obtained to overcome these problems is based on 5W + 1H, namely, Adding 1 welder, Conducting training regularly, Employing certified operators, Making a standard sequence of welding processes, Changing the size of the nozzle with a diameter <18mm, Making agreements with suppliers to process material according to the required specifications, Make maintenance schedules, Determine the number of operators (fix manpower). Keyword: Weld Defect, Pareto Diagram, Fishbone Diagram, FMEA, 5W+1H. PT. Sentra Surya Ekajaya (PT. SSE) adalah salah satu perusahaan di Indonesia yang bergerak di bidang khusus design, engineering, dan manufacturing yang memproduksi kendaraan khusus militer. Berdasarkan pengamatan dilapangan masih dapat ditemukan terjadinya cacat yang tidak dapat terhindarkan dimana quality produk frame P6 ATAV yang dihasilkan pada proses pengelasan tidak sesuai dengan standar kualitas yang ditetapkan oleh perusahaan yaitu 2% atau 5 joint per unit. Oleh karena itu penelitian ini bertujuan untuk menganalisa jenis dan penyebab cacat, serta memberikan usulan perbaikan untuk mengurangi dan mencegah kecacatan pada produk frame P6 ATAV. Metode yang digunakan pada peelitian ini adalah metode Failure Mode and Effect Analysis (FMEA) dengan bantuan tools diagram pareto, diagram fishbone, dan 5W+1H. Hasil akhir dari metode FMEA berupa nilai Risk Priority Number (RPN) yang diperoleh dengan mengalikan severity, occurence, dan detection. Berdasarkan hasil penelitian, terdapat 3 nilai RPN tertinggi yaitu cacat incomplete welding yang disebabkan karena Operator Kelelahan (RPN= 315), Gerakan Ayun Las Kurang Lebar (RPN= 315), dan Tidak Adanya Standar urutan Pengelasan (RPN= 270). Untuk 5 penyebab kegagalan lainnya yaitu Kurangnya pengetahuan standar parameter pengelasan, Sudut sambungan terlalu sempit, Kesalahan proses bending/cutting pada supplier, Terdapat Kerusakan didalam Kabel Nozzle, Operator Sering Berubah-ubah. Usulan yang di dapatkan untuk mengatasi permasalahan tersebut berdasarkan 5W+1H yaitu, Menambah 1 orang welder, Melakukan training secara berkala, Mempekerjakan operator yang sudang tersertifikasi, Membuat standar urutan proses pengelasan, Mengganti ukuran nozzle dengan diameter <18mm, Membuat perjanjian dengan supplier untuk memproses material sesuai dengan spesifikasi yang dibutuhkan, Membuat jadwal maintenance, Penetapan jumlah operator (fix manpower). Kata Kunci: Cacat Pengelasan, Diagram Pareto, Diagram Fishbone, FMEA, 5W+1H.
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