Optimasi Cutting-Fitting Blok Lambung Kapal LPD Dengan Risk-Based Green Lean Six Sigma Dan Response Surface Methodology

Da Murra, Fadhel (2026) Optimasi Cutting-Fitting Blok Lambung Kapal LPD Dengan Risk-Based Green Lean Six Sigma Dan Response Surface Methodology. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Industri galangan kapal dengan karakteristik Engineering-to-Order memiliki variasi proses yang tinggi, terutama pada tahap awal konstruksi blok seperti cutting dan fitting. Ketidakstabilan proses tersebut dapat memicu peningkatan work-in-process (WIP), waktu tunggu, rework, bottleneck, serta konsumsi energi yang tidak efisien. Penelitian ini bertujuan memetakan kondisi aktual proses cutting-fitting, mengidentifikasi sumber hambatan aliran, serta menentukan kombinasi parameter proses yang optimal pada produksi blok lambung kapal Landing Platform Dock di PT PAL Indonesia. Penelitian menggunakan integrasi Risk-Based Green Lean Six Sigma dan Response Surface Methodology dengan kerangka DMAI, yaitu Define, Measure, Analyze, dan Improve. Kondisi aktual dianalisis melalui Current State Value Stream Mapping, perhitungan WIP, throughput, kapasitas, utilisasi, konsumsi energi, analisis bottleneck, root cause analysis, dan risk register. Hasil pemetaan menunjukkan total cycle time sebesar 2.307 menit, waiting time sebesar 2.383 menit, dan lead time sebesar 4.690 menit. Optimasi dilakukan menggunakan Box-Behnken Design dengan 27 kombinasi eksperimen, empat faktor berupa cutting speed, current, gas pressure, dan standoff, serta lima respons berupa TimeCut, Deviation, EdgeQuality, Adjustment, dan Energy. Hasil optimasi menghasilkan parameter terbaik pada cutting speed 400 mm/min, current 89,24 A, gas pressure 5 bar, dan standoff 2 mm dengan nilai composite desirability sebesar 0,91741. Kondisi usulan memprediksi penurunan TimeCut dari 66 menjadi 64,37 menit, Deviation dari 1,26 menjadi 0,91 mm, Adjustment dari 12,44 menjadi 1,11 menit, dan Energy dari 17,50 menjadi 16,92 kWh, serta peningkatan EdgeQuality dari 3,85 menjadi 5,00. Hasil tersebut digunakan sebagai dasar penyusunan Future State Value Stream Mapping dan rekomendasi perbaikan terintegrasi untuk meningkatkan kestabilan aliran proses, kualitas hasil potong, dan efisiensi energi
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The shipbuilding industry, characterized by an Engineering-to-Order production system, exhibits high process variability, particularly during the early stages of block construction such as cutting and fitting. Process instability may lead to increased work-in-process (WIP), waiting time, rework, bottlenecks, and inefficient energy consumption. This study aims to map the current condition of the cutting-fitting process, identify production-flow constraints, and determine the optimal combination of process parameters in the production of Landing Platform Dock hull blocks at PT PAL Indonesia. The study integrates Risk-Based Green Lean Six Sigma and Response Surface Methodology within the DMAI framework, consisting of Define, Measure, Analyze, and Improve. The existing condition was evaluated using Current State Value Stream Mapping, WIP and throughput analysis, capacity and utilization assessment, energy-consumption estimation, bottleneck analysis, root-cause analysis, and a risk register. The current-state analysis resulted in a total cycle time of 2,307 minutes, waiting time of 2,383 minutes, and lead time of 4,690 minutes. Process optimization was conducted using a Box-Behnken Design consisting of 27 Eksperimental runs, four factors which is cutting speed, current, gas pressure, and standoff, and five responses include: TimeCut, Deviation, EdgeQuality, Adjustment, and Energy. The optimization produced an optimal setting of 400 mm/min cutting speed, 89.24 A current, 5 bar gas pressure, and 2 mm standoff, with a composite desirability value of 0.91741. The proposed condition predicts a reduction in TimeCut from 66 to 64.37 minutes, Deviation from 1.26 to 0.91 mm, Adjustment from 12.44 to 1.11 minutes, and Energy from 17.50 to 16.92 kWh, while increasing EdgeQuality from 3.85 to 5.00. These results were used to develop a Future State Value Stream Mapping and integrated improvement recommendations aimed at improving process-flow stability, cutting quality, and energy efficiency.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Bottleneck, Efisiensi Energi, Green Lean Six Sigma, Kapal LPD, Response Surface Methodology
Subjects:	T Technology > T Technology (General) > T174.5 Technology--Risk assessment. T Technology > T Technology (General) > T58.8 Productivity. Efficiency T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control) T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning) T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing.
Divisions:	Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Fadhel Da Murra
Date Deposited:	30 Jul 2026 02:21
Last Modified:	30 Jul 2026 02:21
URI:	http://repository.its.ac.id/id/eprint/140289

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