Analisis Efektivitas Proses Sheet Metal Bending Berdasarkan Identifikasi Losses Pada Produksi Vessel, Trailer, Dan Semi Trailer

Amran, Muhammad Arya Zaydan (2026) Analisis Efektivitas Proses Sheet Metal Bending Berdasarkan Identifikasi Losses Pada Produksi Vessel, Trailer, Dan Semi Trailer. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Produksi vessel, trailer, dan semi trailer pada sistem make-to-order (MTO) menghadapi variasi komponen yang tinggi, sehingga proses bending pada mesin Bending Press Brake (BPB) menunjukkan rendahnya efektifitas mesin akibat besarnya proporsi aktivitas non-value added dan necessary non-value added dibandingkan aktivitas bernilai tambah. Penelitian ini mengintegrasikan Process activity mapping (PAM) dengan Overall Process Effectiveness (OPE), yaitu perluasan dari Overall Equipment Effectiveness (OEE) ke level proses, di mana data hasil pemetaan PAM digunakan langsung sebagai input perhitungan ketiga komponen OPE. Losses dominan yang teridentifikasi kemudian dianalisis menggunakan diagram Pareto, ditelusuri akar penyebabnya melalui root cause analysis (5 Why dan fishbone diagram), dan dirumuskan usulan perbaikannya menggunakan pendekatan Genba Shikumi. Penelitian dilakukan pada Mesin BPB-06 Deratech selama periode observasi 24 Februari hingga 6 Maret 2026. Hasil pengolahan data menunjukkan Availability rate sebesar 43,14%, Performance rate 61,64%, dan Quality Rate 98,86%, sehingga diperoleh nilai OPE rata-rata sebesar 26,29%. Diagram Pareto mengidentifikasi empat losses dominan dengan kontribusi kumulatif 86%, yaitu Man (42%), Material (18%), Reduced Speed (16%), dan Change over (10%). Penelusuran akar permasalahan pada keempat kategori tersebut menghasilkan lima akar penyebab yang bermuara pada ketiadaan standar kerja dan alat bantu visual di lantai produksi. Berdasarkan temuan tersebut, dirumuskan empat usulan perbaikan berupa papan target harian visual, rak job card berlabel, format job card terpadu yang memuat parameter setting mesin, serta papan sequencing work order dengan pendekatan SMED, sebagai rekomendasi bagi perusahaan untuk meningkatkan efektivitas proses bending tanpa memerlukan penambahan mesin atau tooling baru.
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Vessel, trailer, and semi-trailer production under a make-to-order (MTO) system deals with high component variation, which often leaves the bending process on the Bending Press Brake (BPB) machine with low effectiveness because of non-value-added and necessary non-value-added activities dominate over value-added work. This study integrates Process activity mapping (PAM) with Overall Process Effectiveness (OPE), an extension of Overall Equipment Effectiveness (OEE) to the process level, in which PAM observation data is used directly as the input for calculating all three OPE components. The dominant losses identified are analyzed using a Pareto diagram, traced to their root causes through root cause analysis (5 Why and fishbone diagram), and addressed through improvement proposals formulated with the Genba Shikumi approach. The research was conducted on the BPB-06 Deratech machine over an observation period from 24 February to 6 March 2026. Data processing results show an Availability rate of 43.14%, a Performance rate of 61.64%, and a Quality Rate of 98.86%, yielding an average OPE of 26.29%. The Pareto diagram identifies four dominant losses with a cumulative contribution of 86%: Man (42%), Material (18%), Reduced Speed (16%), and Change over (10%). Root cause tracing on these categories produces five root causes, all stemming from the absence of standardized work procedures and visual aids on the shop floor. Four improvement proposals are formulated, namely a visual daily target board, a labeled job card rack, an integrated job card containing machine setting parameters, and a work order sequencing board based on the SMED approach, offered as recommendations for the company to improve bending process effectiveness without additional machinery or tooling.

Item Type: Thesis (Other)
Uncontrolled Keywords: Genba Shikumi, losses, Overall Process Effectiveness, Process activity mapping, sheet metal bending
Subjects: T Technology > TS Manufactures > TS173 Reliability of industrial products
T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering)
Divisions: Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User: Muhammad Arya Zaydan Amran
Date Deposited: 07 Aug 2026 07:49
Last Modified: 07 Aug 2026 07:49
URI: http://repository.its.ac.id/id/eprint/144216

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