Fauzan, Muhammad (2024) Analisis Identifikasi Masalah Sistem Autonomous Maintenance (AM) Pada Mesin Filling Emulsion dengan Pendekatan FMEA dan House of Risk (HOR). Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Latar belakang industri yang kompetitif dan persaingan yang ketat, peningkatan kinerja operasional menjadi krusial dalam mencapai keunggulan kompetitif. proses filling memiliki peran paling krusial dalam menentukan kualitas dan keamanan produk akhir. Mesin filling memastikan konsistensi dan akurasi dalam pengisian cat, hasil produksi atau produktivitas ditentukan oleh hasil finish good yang mana mesin filling berperan utama dalam menghasilkan produk akhir sehingga perlu dijamin ketersediaannya agar dalam prosesnya tidak mengalami downtime dan mencegah semua masalah-masalah yang dapat berpotensi menyebabkan breakdown. Dalam penerapannya AM memang menjadi pilar utama dalam TPM untuk meningkatkan efektivitas dan meminimalkan downtime pada peralatan produksi. Penelitian ini bertujuan untuk mengoptimalkan sistem AM pada mesin filling emulsion di industri cat dengan menggunakan pendekatan FMEA dan House of Risk (HOR). Sebagai strategi utama dalam pemeliharaan mesin, AM menjadi fokus utama dalam upaya meningkatkan kinerja operasional dan mengurangi downtime. Dengan pendekatan ini, penelitian ini bertujuan untuk menyusun strategi penanganan masalah prioritas terbaik yang dapat memberikan dampak signifikan terhadap efektivitas AM. Hasil identifikasi menggunakan FGD dan analisis FMEA, ditemukan 24 masalah dengan 3 akar kritis yang diprioritaskan, yaitu tidak adanya alat monitoring (F3), kurangnya stok sparepart (F4), dan ketiadaan jadwal penggantian part (F1). Strategi penanganan berdasarkan HOR fase-2 mencakup pembuatan sistem monitoring AM (PA1), peningkatan pengawasan melalui penambahan posisi Production Technical Support (PTS) (PA6), dan pembuatan prioritas stok sparepart (PA2). Implementasinya melibatkan pengembangan aplikasi monitoring berbasis portal perusahaan, redesain proses bisnis AM dengan menambah posisi PTS, dan manajemen inventori sparepart menggunakan teori ABC untuk klasifikasi vitalitas part. Hasilnya, rata-rata losses time pada mesin filling emulsion berkurang 56,21% dan capaian nilai OEE meningkat sebesar 4,52%.
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Highly competitive industry, operational performance improvement is crucial for achieving competitive advantage. The filling process plays a pivotal role in determining the quality and safety of the final product. Filling machines ensure consistency and accuracy in paint filling, and the productivity of the process is determined by the output of finished goods, where the filling machine plays a central role in delivering the final product. Therefore, its availability must be guaranteed to prevent downtime and address potential issues that could cause breakdowns. Autonomous Maintenance (AM) serves as a key pillar of Total Productive Maintenance (TPM) to enhance effectiveness and minimize downtime in production equipment. This study aims to optimize the AM system for emulsion filling machines in the paint industry using Failure Mode and Effect Analysis (FMEA) and the House of Risk (HOR) approach. As a primary strategy in machine maintenance, AM is the main focus in efforts to improve operational performance and reduce downtime. Using this approach, the study seeks to develop the best priority problem-solving strategies that can significantly impact AM effectiveness. The results from the identification process using FGD and FMEA analysis, 24 problems were found, with three critical root causes prioritized: the absence of monitoring tools (F3), lack of spare part stock (F4), and no scheduled part replacement (F1). The priority handling strategies based on HOR phase-2 include the development of an AM monitoring system (PA1), enhanced supervision through the addition of a Production Technical Support (PTS) position (PA6), and the creation of a spare part prioritization system (PA2). Implementation involves developing a monitoring application integrated into the company's portal, redesigning AM business processes by adding the PTS role, and managing spare part inventory using the ABC classification method for vital part prioritization. As a result, the average losses time on the emulsion filling machine decreased by 56.21%, and the OEE value increased by 4.52%.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Autonomous Maintenance, Downtime, House of Risk, Perawatan Mandiri, Waktu henti, Rumah risiko. |
| Subjects: | T Technology > T Technology (General) > T174.5 Technology--Risk assessment. T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering) |
| Divisions: | Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT) |
| Depositing User: | Muhammad Fauzan |
| Date Deposited: | 15 Jan 2025 03:01 |
| Last Modified: | 15 Jan 2025 03:01 |
| URI: | http://repository.its.ac.id/id/eprint/116301 |
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