Qodhar, Rahfi Abdul (2025) Peningkatan Efisiensi Dan Kesehatan Operator Pada Perusahaan Pelek Roda Baja (PRB) Dengan Theory Of Constraints (TOC) Dan Ovako Work Posture Analysis System (OWAS). Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Perusahaan Pelek Roda Baja (PRB) adalah perusahaan Original Equipment Manufacturers (OEM) pelek roda baja untuk kendaraan komersial seperti truk dan bus. Perusahaan ini memiliki 5 lini produksi, di antaranya rim line, side ring line, disc line, assembly line, dan painting line. Berdasarkan data historis dan kondisi aktual perusahaan, rim line memiliki tingkat reject rate yang tinggi dan melebihi standar (> 0,20%) selama periode rata-rata tahun 2024, bulan Januari, dan bulan Februari 2025. Permasalahan terkait bottleneck juga terindikasi dengan rendahnya efektivitas operasional yang dapat dilihat dari rendahnya Overall Equipment Effectiveness (OEE) sebesar 54,13% jika dibandingkan dengan production line lainnya. Selain itu, adanya risiko kecelakaan kerja dan cedera Work-related Musculoskeletal Disorders (WMSD) akibat postur kerja yang tidak ergonomis menjadi permasalahan yang dialami Perusahaan PRB. Penelitian ini bertujuan untuk mengatasi bottleneck produksi, mengurangi reject rate, dan meningkatkan kesehatan operator melalui perbaikan postur kerja. Metode penelitian yang digunakan adalah integrasi metode dari Theory of Constraints (TOC), konsep six sigma, dan Ovako Work Posture Analysis System (OWAS). Theory of Constraints (TOC) diterapkan dengan 5 langkah kerja TOC dimulai dari identify the constraint, exploit the constraint, subordinate everything else, elevate the constraint, dan repeat the process. Konsep six sigma digunakan untuk mengatasi permasalahan reject rate. Metode Ovako Work Posture Analysis System (OWAS) digunakan untuk mengidentifikasi postur kerja, menilai risiko postur tubuh, dan memberikan peluang perbaikan postur. Hasil penelitian ini adalah peningkatan throughput mesin flash butt welding dari 934 unit menjadi 1200 unit. Peningkatan nilai Pp, Ppk, dan sigma score mesin flash butt welding dari Pp=0,82, Ppk=0,71, sigma score=3,12 menjadi Pp=1,15, Ppk=0,70, sigma score=3,59. Penurunan skor OWAS dari 2 menjadi 1 karena perbaikan postur punggung dan pengurangan berat benda kerja karena penggunaan handling tool.
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Perusahaan Pelek Roda Baja (PRB) is an Original Equipment Manufacturers (OEM) of steel wheel rims for commercial vehicles such as trucks and buses. The company has 5 production lines, including rim line, side ring line, disc line, assembly line, and painting line. Based on historical data and the company's actual conditions, the rim line had a high reject rate that exceeded the standard (>0.20%) during the average period of 2024, January, and February 2025. Bottleneck-related problems are also indicated by the low operational effectiveness which can be seen from the low Overall Equipment Effectiveness (OEE) of 54.13% when compared to other production lines. In addition, the risk of work accidents and Work-related Musculoskeletal Disorders (WMSD) injuries due to non-ergonomic work postures is a problem experienced by PRB Company. This research aims to overcome production bottlenecks, reduce reject rates, and improve operator health through improved work posture. The research method used to answer the research objectives is the integration of methods from the Theory of Constraints (TOC), the six sigma concept, and the Ovako Work Posture Analysis System (OWAS). The Theory of Constraints (TOC) method was applied with 5 work steps, including identify the constraint, exploit the constraint, subordinate everything else, elevate the constraint, and repeat the process. The six sigma concept is used to overcome the reject rate problem. The Ovako Work Posture Analysis System (OWAS) method was used to identify work postures, assess posture risks, and provide posture improvement opportunities. The result of this research is an increase in the throughput of the flash butt welding machine from 934 units to 1200 units. Increased Pp, Ppk, and sigma score of flash butt welding machine from Pp=0.82, Ppk=0.71, sigma score=3.12 to Pp=1.15, Ppk=0.70, sigma score=3.59. The decrease in OWAS score from 2 to 1 is due to improved back posture and reduction in workpiece weight due to the use of handling tools.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Theory of Constraints (TOC), Ovako Work Posture Analysis System (OWAS), Six Sigma, Bottleneck, Throughput, Theory of Constraints (TOC), Ovako Work Posture Analysis System (OWAS), Six Sigma, Bottleneck, Throughput. |
| Subjects: | T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing. |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | Rahfi Abdul Qodhar |
| Date Deposited: | 14 Jul 2025 04:15 |
| Last Modified: | 14 Jul 2025 04:15 |
| URI: | http://repository.its.ac.id/id/eprint/119596 |
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