Peningkatan Efisiensi dan Kualitas di Pabrik Beras Magetan Menggunakan Integrasi Lean Manufacturing dan Failure Reporting Analysis and Corrective Action System (FRACAS)

Leriesta, Augie Diva (2025) Peningkatan Efisiensi dan Kualitas di Pabrik Beras Magetan Menggunakan Integrasi Lean Manufacturing dan Failure Reporting Analysis and Corrective Action System (FRACAS). Other thesis, Institut Teknologi Sepuluh Nopember.

Text 5010211036-Undergraduate_Thesis.pdf - Accepted Version Restricted to Repository staff only Download (2MB) | Request a copy

Abstract

Dalam upaya pemenuhan kebutuhan beras di Indonesia masih terdapat kendala, salah satunya adalah terganggunya produktivitas padi yang juga disebabkan oleh kerusakan mesin yang terjadi pada proses produksi di Pabrik Beras Magetan dan adanya hama. Masih ditemukannya kegagalan yang terjadi dapat mengindikasikan bahwa proses produksi beras belum berjalan secara efisien dan dapat mengakibatkan munculnya waste di lantai produksi, seperti waiting. Adanya hama juga dapat menyebabkan terjadinya defect pada beras sehingga dapat mengurangi kualitas bahkan kuantitas beras. Penyelesaian permasalahan tersebut dapat menggunakan pendekatan Lean Manufacturing dan Failure Reporting Analysis and Corrective Action System (FRACAS). Dalam mengidentifikasi waste dibantu menggunakan beberapa tool, seperti Value Stream Mapping (VSM) dan Yamazumi Chart yang kemudian akar penyebab terjadinya masalah dianalisis menggunakan Fishbone Diagram sehingga dapat diusulkan perbaikan, yakni dengan merancang jadwal pemeliharaan menggunakan metode Inspection Repair Replace Overhaul (IRRO), penjadwalan produksi dengan melakukan demand forecasting, dan pembuatan form FRACAS. Dengan begitu, efisiensi produksi dan kualitas produk dapat meningkat dimana tingkat efisiensi dapat diukur menggunakan indeks Overall Equipment Effectiveness (OEE). Tingkat OEE eksisting sebesar 163,27% dengan availability rate sebesar 96,11%, performance rate sebesar 264,74%, dan quality rate sebesar 65,25%. Setelah adanya usulan perbaikan, nilai OEE – nya menjadi 111,29% dengan availability rate sebesar 99,78%, performance rate sebesar 159,34%, dan quality rate sebesar 70%. Meskipun terjadi penurunan nilai OEE secara keseluruhan, tetapi hasil tersebut sudah cukup baik melihat adanya kenaikan pada availability rate dan quality rate serta OEE yang mendekati angka 100%.
========================================================================================================================================
In efforts to meet rice needs in Indonesia, there are still obstacles, one of which is the disruption of rice productivity which is also caused by machine damage that occurs in the production process at the Magetan Rice Factory and the presence of pests. The continued discovery of failures can indicate that the rice production process is not running efficiently and can result in waste on the production floor, such as waiting. The presence of pests can also cause defects in rice, thereby reducing the quality and even quantity of rice. Solving these problems can use the Lean Manufacturing approach and the Failure Reporting Analysis and Corrective Action System (FRACAS). In identifying waste, it is assisted by using several tools, such as Value Stream Mapping (VSM) and Yamazumi Chart, then the root cause of the problem is analyzed using a Fishbone Diagram so that improvements can be proposed, specifically by designing a maintenance schedule using the Inspection Repair Replace Overhaul (IRRO) method, production scheduling by conducting demand forecasting, and creating a FRACAS form. In this way, production efficiency and product quality can be increased, where the efficiency level can be measured using the Overall Equipment Effectiveness (OEE) index. The existing OEE level is 163.27% with an availability rate of 96.11%, a performance rate of 264.74%, and a quality rate of 65.25%. After the proposed improvements, the OEE value became 111.29% with an availability rate of 99.78%, a performance rate of 159.34%, and a quality rate of 70%. Although there was a decrease in the overall OEE value, the results were quite good considering the increase in the availability rate and quality rate as well as the OEE approaching 100%.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Fishbone Diagram, FRACAS, Lean Manufacturing, Overall Equipment Effectiveness (OEE), Value Stream Mapping (VSM)
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:	Augie Diva Leriesta
Date Deposited:	28 Jul 2025 09:54
Last Modified:	28 Jul 2025 09:54
URI:	http://repository.its.ac.id/id/eprint/122779

Actions (login required)

View Item