Geovanni, Leonardo (2026) Evaluasi Tpm Kabel Harness Pada Mesin HASS Burn-in Chamber Untuk Meningkatkan Produktivitas Modul MAU Di Perusahaan Manufacturing Aerospace. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Inefisiensi pengujian Highly Accelerated Stress Screening (HASS) pada produk Modular Avionics Unit (MAU) diidentifikasi sebagai penghambat utama produktivitas di perusahaan manufaktur aerospace. Penelitian ini dilakukan untuk mengevaluasi penerapan Total Productive Maintenance (TPM) pada komponen kabel harness guna mereduksi downtime dan mengungkap "pabrik tersembunyi" (hidden factory). Metodologi penelitian mencakup pengumpulan data operasional historis tiga tahun, perhitungan Overall Equipment Effectiveness (OEE) aktual yang dimodifikasi dengan standar First Pass Yield (FPY), serta analisis akar masalah menggunakan diagram Fishbone 6M. Validasi analisis dilaksanakan melalui kuesioner terhadap 30 responden dari departemen Produksi dan Maintenance. Metrik keandalan teknis seperti Mean Time Between Failures (MTBF) dan Mean Time To Repair (MTTR) dihitung untuk menetapkan interval perawatan preventif. Hasil penelitian menunjukkan bahwa nilai OEE aktual stasiun HASS hanya sebesar 77,05% dan berada di bawah standar World Class OEE (85%), meskipun laporan internal mengklaim 94%. Rendahnya keandalan kabel dengan nilai MTBF 236,81 jam memicu fenomena kegagalan palsu (false failure) yang mengakibatkan kerugian finansial (Cost of Poor Quality) sebesar Rp 2.356.160.000. Usulan perbaikan dirumuskan melalui pilar Autonomous Maintenance (AM) dengan integrasi instrumen Poka-Yoke visual dan Planned Maintenance (PM) berbasis keandalan. Implementasi rekayasa visual diproyeksikan meningkatkan efisiensi waktu penyetelan (setup) hingga 80%. Implikasi manajerial ditekankan pada transformasi budaya perawatan dari reaktif (run-to-failure) menjadi proaktif guna menjamin stabilitas kapasitas produksi dan ketepatan pengiriman (On-Time Delivery).
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Inefficiencies in Highly Accelerated Stress Screening (HASS) testing of Modular Avionics Units (MAUs) have been identified as a major obstacle to productivity in aerospace manufacturing companies. This study evaluates the implementation of Total Productive Maintenance (TPM) on cable harness components to reduce downtime and uncover “hidden factories.” The research methodology includes the collection of three years of historical operational data, calculation of actual Overall Equipment Effectiveness (OEE) adjusted for First Pass Yield, and root cause analysis using the 6M Fishbone diagram. The analysis is validated through a questionnaire administered to 30 respondents from the Production and Maintenance departments. Technical reliability metrics, including Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR), are calculated to determine appropriate preventive maintenance intervals. The results show that the actual OEE value of the HASS station is only 77.05%, which is below the World Class OEE standard of 85%, despite internal reports indicating a value of 94%. Low cable reliability, with an MTBF of 236.81 hours, triggers false failures that result in a financial loss (Cost of Poor Quality) of Rp2,356,160,000. Improvement proposals are formulated through the Autonomous Maintenance (AM) framework by integrating visual Poka-Yoke tools and reliability-based Planned Maintenance (PM). The implementation of visual engineering is projected to improve setup time efficiency by up to 80%. The managerial implications emphasize the need for a cultural shift in maintenance practices from a reactive (“run-to-failure”) approach toward a proactive strategy to ensure production capacity stability and on-time delivery. **Keywords:** Total Productive Maintenance (TPM), Overall Equipment Effectiveness (OEE), Cost of Poor Quality (COPQ), Poka-Yoke, Aerospace.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Total Productive Maintenance (TPM), Overall Equipment Effectiveness (OEE), Cost of Poor Quality (COPQ), Poka-Yoke, Aerospace. |
| Subjects: | T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control) T Technology > TS Manufactures > TS161 Materials management. T Technology > TS Manufactures > TS167 Costs, Industrial T Technology > TS Manufactures > TS173 Reliability of industrial products 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: | Leonardo Geovanni |
| Date Deposited: | 04 Aug 2026 07:41 |
| Last Modified: | 04 Aug 2026 07:41 |
| URI: | http://repository.its.ac.id/id/eprint/142149 |
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