Winarno, Edi (2024) Kajian Layout Proses Finishing Produksi Kereta Api PT INKA (Persero) Dengan Metode Systematic Layout Planning. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
PT INKA adalah perusahaan manufaktur sarana transportasi berbasis rel dengan karakteristik job order yang telah mengalami perkembangan signifikan dalam jumlah dan jenis produk yang diproduksi. Peningkatan kapasitas produksi dan peningkatan kualitas terus-menerus dijalankan. Kebijakan investasi diarahkan untuk peremajaan mesin dan penataan kembali fasilitas produksi di pabrik Madiun dan penyiapan pabrik baru di Banyuwangi. Inefisiensi dalam proses produksi masih ditemukan dimana pemborosan berupa waiting, over processing, motion dan transportasion, adalah empat besar pemborosan yang terjadi (Herwindo 2017). Pemborosan waiting, motion, transportation adalah pemborosan yang saling terkait. Pemborosan waiting terjadi karena transportasi dimana jarak antar proses berjauhan, ketidak cukupan ruang sehinggan terjadi bottle neck, motion juga disebabkan oleh banyaknya produk/material yang dipindahkan karena proses yang menyebar. Tata letak pabrik, khususnya pada tahap painting, menjadi kritis karena produk memiliki dimensi besar dan menggunakan moda berbasis rail untuk perpindahan antar stasiun proses. Penelitian ini bertujuan untuk mengidentifikasi dan menganalisis data-data perusahaan yang meliputi jenis produk, target kapasitas produksi, alur proses, dukungan layanan, waktu proses, dan jam kerja terkait dengan kebutuhan dan ketersediaan area kerja serta penataan lokasinya. Berdasarkan analisis, beberapa alternatif layout dibuat dan dilakukan pemilihan layout terbaik untuk re-layout proses painting gerbong barang, kereta penumpang, dan kereta berpenggerak. Metode Systematic Layout Planning (SLP) digunakan dalam penelitian ini. Tahapan perencanaan tata letak melibatkan identifikasi produk (P), kuantitas (Q), perutean (R), dukungan layanan (S), dan waktu (T), diikuti dengan pendaftaran area aktivitas, analisis aliran material, serta hubungan lain yang dijelaskan dalam suatu diagram hubungan. Evaluasi kebutuhan ruang, pembuatan diagram hubungan spasial, dan analisis kendala serta keterbatasan sebagai pertimbangan pembuatan alternatif layout yang kemudian dievaluasi untuk dipilih sebagai layout terbaik. Hasil penelitian menunjukkan bahwa dari dua alternatif layout untuk proses painting kereta penumpang/berpenggerak, layout alternatif pertama dengan tambahan rail bypass dan perpanjangan jalur transverser adalah layout terbaik, memberikan efisiensi ongkos material handling 21.68% terhadap laytout painted body dan 32.28% terhadap layout unpainted saat ini dan dari tiga alternatif layout untuk proses painting gerbong barang, layout alternatif pertama adalah layout terbaik, memberikan efisiensi ongkos material handling lebih dari 26% terhadap layout line 1 dan layout line 2 saat ini.
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PT. INKA is a rail-based transportation facility manufacturing company with job order characteristics that has experienced significant developments in the number and types of products produced. Increasing production capacity and improving quality are continuously carried out. The investment policy is directed at rejuvenating machines and reorganizing production facilities at the Madiun factory and preparing a new factory in Banyuwangi. Inefficiencies in the production process are still found where waste in the form of waiting, over processing, motion and transportation, are the four major wastes that occur (Herwindo 2017). Waiting, motion, transportation waste are interrelated wastes. Waiting waste occurs due to transportation where the distance between processes is far apart, there is insufficient space resulting in bottle necks, motion is also caused by the large number of products/materials being moved because the process is spread out. Factory layout, especially at the painting stage, is critical because the product has large dimensions and uses a rail-based mode for movement between processing stations. This research aims to identify and analyze company data which includes product type, target production capacity, process flow, service support, processing time and working hours related to the need and availability of work areas and location arrangement. Based on the analysis, several alternative layouts were created and the best layout was selected for the re-layout of the painting process for goods carriages, passenger trains and propelled trains. The Systematic Layout Planning (SLP) method was used in this research. The layout planning stages involve identification of product (P), quantity (Q), routing (R), service support (S), and time (T), followed by registration of activity areas, material flow analysis, as well as other relationships described in a relationship diagram. Evaluate space requirements, create spatial relationship diagrams, and analyze constraints and limitations as considerations for creating alternative layouts which are then evaluated to be selected as the best layout. The research results show that of the two alternative layouts for the painting process for passenger/propelled trains, the first alternative layout with the addition of a bypass rail and extension of the transverser track is the best layout, providing a material handling cost efficiency of 21.68% for the current painted body layout and 32.28% for the current unpainted layout. and of the three alternative layouts for the goods carriage painting process, the first alternative layout is the best layout, providing material handling cost efficiency of more than 26% compared to the current line 1 and line 2 layouts.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | PT INKA, Pemborosan, Proses Painting, Re-layout, Systematic Layout Planning (SLP), Tata Letak Pabrik, Painting Process |
| Subjects: | N Fine Arts > ND Painting T Technology > TD Environmental technology. Sanitary engineering > TD899 Waste control in special industries, plants, processes, etc T Technology > TF Railroad engineering and operation T Technology > TH Building construction > TH385 Building layout. |
| Divisions: | Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT) |
| Depositing User: | Edi Winarno |
| Date Deposited: | 23 Jul 2024 02:10 |
| Last Modified: | 23 Jul 2024 02:10 |
| URI: | http://repository.its.ac.id/id/eprint/108709 |
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