PT. Agronesia Inkaba adalah Badan Usaha Milik Daerah (BUMD), yang bergerak di industri karet. PT. Agronesia Inkaba sering mengalami permasalahan breakdown mesin yang tinggi pada mesin utama yaitu kneader KD-75-150D. Berdasarkan hasil wawancara, diketahui downtime yang terjadi pada mesin kneader KD 75-150D selama tahun 2017 yaitu sebesar 152,26 jam dengan jumlah kerusakan sebanyak 29 kali dengan total kerugian sebesar Rp. 105.352.184. Identifikasi masalah dilakukan dengan metode menggunakan metode Reliability Centered Maintenance (RCM). Berdasarkan hasil nilai RPN tertinggi diperoleh 3 komponen kritis yaitu Seal Packing, Bearing, Belt. Maka tujuan penelitian ini adalah menjadwalkan preventive maintenance ketiga komponen kritis tersebut. Metode yang digunakan untuk menentukan jadwal interval pergantian komponen yaitu age replacement dan group replacement untuk meminimasi. Setelah melakukan kebijakan preventive maintenance menggunakan age replacement terjadi penurunan downtime menjadi 79,8 jam. Waktu pergantian untuk setiap komponennya adalah 28 hari seal packing, bearing 38 hari dan belt 41 hari. Untuk metode group replacement menghasilkan interval waktu pergantian setiap 34 hari sekali dengan total pergantian sebanyak 10 kali dalam 1 tahun dengan total downtime 76,8 jam pertahun. Total biaya corrective maintenance sebesar Rp. 80.730.998 per tahun, sedangkan biaya penggantian preventive maintenance menggunakan age replacement sebesar Rp. 66.177.601 pertahun dan menggunakan group replacement sebesar Rp. 65.603.670 per tahun. Dengan demikian group replacement dinilai lebih efisien dan dapat mempersingkat waktu yang dibutuhkan untuk melalukan pergantian komponen yang rusak karena pergantian dilakukan secara bersamaan.
PT HPPM is a manufacturing company engaged in the automotive sector. The products produced include Automatic Transmission (ATM), Engine Valve (EV), Four Wheel Drive (4WD), and Stell Belt, which are marketed at home and abroad. In carrying out its production activities, PT HPPM has guidelines for controlling its products' quality to compete in the automotive industry, including ATM products with the MCVT (Medium Continuously Variable Transmission) model. The method used in the quality control analysis of this research is Six Sigma, a vision of quality improvement towards a target of 3,4 failures per million opportunities for every transaction of goods and services, Gasperz (2005). To apply the Six Sigma concept, a measurement method is needed to assist the implementation of Six Sigma in the company. There are five steps in this method's stages, namely DMAIC (Define, Measure, Analyze, Improve, Control). There are four potential Critical To Quality (CTQ) that cause the product to become defective or fail in the MCVT model, namely NG Leak, NG Gata, NG Circlip, and NG OPC. The highest defect is NG Leak defect, 127 units with a percentage of 45.68% of the total number of defects produced-then followed by defects NG Gata with 79 units with a percentage of 28.42%. Meanwhile, another defect is NG Circlip, with 62 units with a percentage of 22.30%, then NG OPC as many as ten units with a percentage of 3.60%. By using the Six Sigma method and the DMAIC step (Define, Measure, Analyze, Improve, Control), it can be seen that the quality of MCVT products in the Main Line 1 process is good, which is at the level of 4,876 sigma with 370 Defect Per Million Opportunity (DPMO). From the Define stage by mapping and identifying problems to find out the causes of defective products, the Measure Stage by calculating the stability of the poses using the SPC method to determine the Proportion, CL, UCL, and LCL and calculating the process capability to determine the sigma level value and the DPMO value. The Analyze stage identifies the source of the problem with the Fishbone Diagram, the Improve stage looks for solutions using the 5W1H method, then Control to maintain and maintain process improvements. The results showed a decrease in the DPMO value from 383 units to 370 and an increase in the sigma level value from 4,868 to 4,876. This shows that the company has been able to implement a good quality control system.
PT. X is a garment company in Cimahi, West Java which consists of four departments, namely texturizing, twisting, weaving and dyeing printing. Research focused weaving department with identifying the cause of the defect with six sigma method Define, Measure, Analyze, and Improve. Based on the identification issue using the steps define, measure and analyze known that the causes of defective products is declining performance nozzle and pump components resulting in less water pressure or excess. In addition, not component replacement for a worn shedding motion so that a malfunction of kamran. Therefore, the purpose of this study was to schedule preventive maintenance on spare nozzle, pump and kamran. Improve these problems by creating a preventive maintenance schedule by age replacement method. Based on the results obtained scheduling data processing component replacement on the machine water jet loom is; (1) The components of the pump will be replaced every 150 days, (2) Components kamran 71 days and (3) Components nozzle 82 days.
PT. XYZ merupakan perusahaan yang dihasilkan kain grey jenis denim. Pada salah produknya yaitu kain 1455 biru tua terdapat 8 jenis cacat yaitu cacat pakan carang, pakan putus, pakan dobel, pakan kosong, pakan ngambang, lusi putus, lusi tegang dan lusi kendor. Berdasarkan identifikasi sebagian besar disebabkan oleh faktor mesin, yaitu cacat pakan putus, pakan kosong, pakan ngambang, lusi putus, dan lusi tegang. Salah satu mesin tenun yang digunakan merk Picanol GTX seri 22844 dengan 30 komponen. Komponen yang kritis karena sering mengalami kerusakan yaitu Dobby, Hamess Transmition, Leno Device, Harness Guiede, Take Up Motion, dan Bearing Beam. Selama 2017, mesin ini mengalami kerusakan sebanyak 36 kali dengan total downtime 16,22 Jam. PT. XYZ belum memiliki sistem perawatan yang terjadwal dengan baik, sehingga menyebabkan sering terjadinya kerusakan mesin dengan downtime yang tinggi. Penelitian ini mengusulkan jadwal preventive maintenance berupa jadwal interval perawatan untuk komponen kritis untuk meningkatkan keandalan komponen mesin dan meminimasi downtime. Dari hasil pengolahan data diperoleh hasil jadwal interval waktu perawatan komponen mesin Picanol GTX seri 22844 adalah; 1) Komponen Dobby dengan jadwal preventive maintenance setiap 18 hari dan peningkatan keandalan 3,84% serta ekspektasi downtime 2,4 jam. 2) Komponen Hamess Transmition dengan jadwal preventive maintenance setiap 20 hari dan peningkatan keandalan 2,23%serta ekspektasi downtime 1,61 jam. 3) Komponen Leno device dengan jadwal preventive maintenance setiap 29 hari dan peningkatan keandalan 2,25% serta ekspektasi downtime 1,06 jam. 4) Komponen Harness Guiede dengan jadwal preventive maintenance 12 hari dan peningkatan keandalan 2,2% Serta ekspektasi downtime 1,18 jam. Setiap komponen memiliki jadwal interval preventive maintenance yang berdekatan, maka untuk menghindari terhambatnya proses produksi karena dilakukan preventive maintenance yang berdekatan harinya maka perawatan akan dilakukan pada satu hari diantara interval preventive maintenance setiap komponen yaitu perawatan akan dilakukan setiap 20 hari.
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