Fabianto, Farhan (2026) Rancangan Pendekatan Integratif (Lean Manufacturing Dan Total Productive Maintenance) Dalam Manajemen Manufaktur Untuk Mendukung Peningkatan Efisiensi Operasional Pada Industri Kaca. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
area Cold End dapat memengaruhi aliran proses, output, dan kualitas produk. Penelitian ini bertujuan menganalisis Loss dominan pada Line 400T/B1 Cold End serta menyusun rancangan perbaikan berbasis integrasi Lean Manufacturing dan Total Productive Maintenance (TPM). Penelitian dilakukan sebagai studi kasus dengan menggunakan data operasional periode 15 Januari–31 Maret 2026. Analisis dilakukan secara bertahap melalui pengukuran Overall Equipment Effectiveness (OEE), pemetaan Six Big Losses, analisis Pareto, penentuan Vital Few, estimasi MTBF/MTTR operasional, Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), serta penyusunan rancangan perbaikan dan Value Stream Mapping (VSM). Hasil penelitian menunjukkan bahwa OEE baseline Line 400T/B1 sebesar 83,24%, dengan Availability 97,28%, Performance 88,28%, dan Quality 96,92%. Total Mapped Loss pada VSM Current State tercatat sebesar 3.812 menit dengan 714 kejadian. Loss prioritas yang ditemukan mencakup Quality Detection and process defect, robot handling and vacuum transfer, Y-Bridge/Long Cut Instability, Cutting Bridge/Cross Cut/Emergency Drop, Tail Pack/Changeover/Order-spec Loss, dan Upstream Carryover Defect. Pada analisis MTBF/MTTR, terdapat 80 kejadian breakdown yang memenuhi kriteria inti dengan total durasi 946 menit, MTBF sebesar 1.330,88 menit/kejadian, dan MTTR sebesar 11,82 menit/kejadian. Rancangan usulan perbaikan yang disusun meliputi Action Plan Lean-TPM, 15 item prioritas dan frekuensi PM yang dipetakan ke 15 rancangan awal Job Plan PM, Standard Work Changeover, Quality Feedback Loop, dan VSM Future State. Berdasarkan proyeksi analitis, Mapped Loss diperkirakan turun menjadi 2.603 menit dengan 491 kejadian, sedangkan OEE diproyeksikan meningkat menjadi 87,52%. Nilai Future State tersebut masih memerlukan validasi melalui implementasi dan monitoring pada periode berikutnya.
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Operational efficiency in the glass industry needs to be controlled because disruptions in the Cold End area can affect process flow, production output, and product Quality. This study aims to analyze the dominant Losses on the 400T/B1 Cold End Line and to develop an improvement design based on the integration of Lean Manufacturing and Total Productive Maintenance (TPM). The research was conducted as a case study using operational data from 15 January to 31 March 2026. The analysis was carried out in stages through Overall Equipment Effectiveness (OEE), Six Big Losses Mapping, Pareto Analysis, Vital Few identification, operational MTBF/MTTR estimation, Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), improvement design, and Value Stream Mapping (VSM). The results show that the baseline OEE of the 400T/B1 Line was 83.24%, with Availability of 97.28%, Performance of 88.28%, and Quality of 96.92%. The total Mapped Loss in the VSM Current State was 3,812 minutes with 714 events. The priority Losses identified in this study consist of Quality Detection and process defect, robot handling and vacuum transfer, Y-Bridge/Long Cut Instability, Cutting Bridge/Cross Cut/Emergency Drop, Tail Pack/Changeover/Order-spec Loss, and Upstream Carryover Defect. The MTBF/MTTR analysis identified 80 core breakdown events that met the analysis criteria, with a total duration of 946 minutes, an MTBF of 1,330.88 minutes per event, and an MTTR of 11.82 minutes per event. The proposed improvement design includes a Lean-TPM Action Plan, 15 prioritized PM items with recommended frequencies mapped to 15 preliminary PM job-plan drafts, Standard Work Changeover, a Quality Feedback Loop, and a VSM Future State. Based on the analytical projection, the Mapped Loss is expected to decrease to 2,603 minutes with 491 events, while OEE is projected to increase to 87.52%. The Future State values still require validation through implementation and monitoring in the following period.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Efisiensi Operasional; Industri Kaca; Lean Manufacturing; Overall Equipment Effectiveness; Total Productive Maintenance |
| Subjects: | T Technology > TS Manufactures > TS155 Production control. Production planning. Production management T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering) T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning) T Technology > TS Manufactures > TS183 Manufacturing processes. Lean manufacturing. |
| Divisions: | Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT) |
| Depositing User: | Farhan Fabianto |
| Date Deposited: | 03 Aug 2026 08:41 |
| Last Modified: | 03 Aug 2026 08:41 |
| URI: | http://repository.its.ac.id/id/eprint/143024 |
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