Analisa Overall Equipment Effectiveness Untuk Memperbaiki Sistem Perawatan Mesin DOP Berbasis Total Productive Maintenance

ANALISA OVERALL EQUIPMENT EFFECTIVENESS UNTUK MEMPERBAIKI SISTEM PERAWATAN MESIN DOP BERBASIS TOTAL PRODUCTIVE MAINTENANCE
Penulis : Baharuddin Yusuf, ARIF RAHMAN & Rakhmat Himawan

Abstrak : Penelitian dilakukan di bengkel link belt. Pada proses pembuatan link belt, kegagalan proses machining di mesin DOP menyebabkan tingginya downtime dan defect. Upaya pengurangan downtime dan defect dapat dilakukan melalui manajemen perawatan menggunakan konsep Total Productive Maintenance (TPM). Penelitian ini mempergunakan metode TPM dengan alat analisa meliputi Overall Equipment Effectiveness (OEE), Six Big Losses dan Fault Tree Analysis (FTA). Tahap pertama yang dilakukan adalah mengukur nilai OEE mesin DOP dan mengidentifikasi Six Big Losses. Tahap selanjutnya membuat diagram FTA untuk mengetahui akar penyebab kerusakan serta probabilitas kegagalannya. Tahap terakhir adalah memberikan rekomendasi perbaikan berbasis prinsip TPM. Hasil perhitungan menunjukkan bahwa rata-rata nilai OEE mesin DOP adalah 70.37%. Penyebab rendahnya nilai OEE adalah setup and adjustment losses dan process defect losses. Setup and adjustment losses terindikasi dengan waktu setup matris sebesar 190-200 menit. Process defect losses terindikasi dengan defect yang dihasilkan selama proses permesinan yang menyebabkan matris aus. Berdasarkan analisa mempergunakan FTA dan prinsip TPM, direkomendasikan perbaikan meliputi membuat toolbox yang dilengkapi toolpallet serta memberikan jadwal perawatan mesin DOP, mengganti dan mengasah matris potong yang tumpul setiap 13 hari.
Kata kunci : total productive maintenance, overall equipment effectiveness, six big losses, fault tree analysis

INVENTORY CONTROL OF SPARE PARTS OF CIGARETTE FILTER MACHINE D3E WITH PROBABILISTIC INVENTORY MODELS

Abstract : This study observes in the link belt workshop. During link belt processing, a failure of machining process in machine DOP triggers downtime and defect. To reduce downtime and defects, it should conduct maintenance management using the principles of Total Productive Maintenance (TPM). The study uses TPM method with tools of Overall Equipment Effectiveness (OEE), Six Big Losses and Fault Tree Analysis (FTA). First, it measures OEE of machine DOP ​​and identifies Six Big Losses. Then, it constructs FTA to determine the root cause of failure and its probability. Last, it recommends some improvement based on the principles of TPM. The OEE value of machine DOP is 70.37%. The OEE value is too low because of setup and adjustment losses and process defect losses. Setup and adjustment losses are indicated by the tool setup time of 190-200 minutes. Process defect losses are indicated by the defect produced during the machining process since tool wear. Based on an analysis using FTA and TPM principles, it recommends to make toolbox with toolpallet and plan machine DOP maintenance schedule, replace tool every 13 days.
Keywords : total productive maintenance, overall equipment effectiveness, six big losses, fault tree analysis

Artikel dipublikasikan dalam Jurnal Rekayasa dan Manajemen Sistem Industri Vol 3 No 1 thn 2015, pp 99-109
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