Putera, Bagas Saestu Adi (2020) REDUKSI SIX BIG LOSSES MENGGUNAKAN PENDEKATAN OVERALL EQUIPMENT EFFECTIVENESS (OEE) DAN TEORIJA RESENIJA ISOBRETATELSKIH ZADAC (TRIZ) PADA PABRIK HOT STRIP MILL (HSM) PT. KRAKATAU STEEL (PERSERO) TBK. Other thesis, InstitutTeknologi Sepuluh Nopember.
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Abstract
Pabrik Hot Strip Mill (HSM) merupakan salah satu pabrik Hot Rolled Coil (HRC) yang bergerak di bawah naungan PT. Krakatau Steel (Persero) Tbk. Dalam proses produksi HRC, pabrik HSM mengalami beberapa permasalahan antara lain defect product yang melebihi target maksimum, seringnya penggantian part mesin, dan mesin mati secara mendadak. Hal ini terjadi karena Pabrik HSM memiliki enam mesin yang sudah tua dan bergerak secara seri dalam proses produksi Hot Rolled Coil (HRC), diantaranya yaitu mesin reheating furnace, sizing press, roughing mill, finishing mill, laminar cooling, dan down coiler. Untuk itu pada penelitian ini akan dilakukan proses perbaikan menggunakan framework Define-Measure-Analysis-Improve-Control (DMAIC) sebagai acuan untuk memperbaiki proses produksi HRC. Dengan menggunakan parameter availability, performance rate, dan quality rate sebagai nilai ukur efektifitas performansi mesin dalam metode Overall Equipment Effectiveness (OEE), parameter OEE tersebut akan diuraikan menjadi Six Big Losses. Selanjutnya akar permasalahan Six Big Losses digunakan sebagai input Failure Mode and Effect Analysis (FMEA) untuk mengetahui urutan prioritas dari permasalahan yang terjadi (critical failure), sehingga dapat menjadi acuan dalam merekomendasikan perbaikan. Rekomendasi perbaikan dilakukan menggunakan TRIZ Method yaitu menawarkan solusi yang terbaik melalui pendekatan baru dengan menemukan tradeoff di balik masalah tersebut. Rekomendasi perbaikan diestimasikan mampu meningkatkan nilai OEE pada mesin reheating furnace dari yang sebelumnya 66,34% menjadi 75,65%, mesin sizing press dari yang sebelumnya 52,44% menjadi 66,62%, mesin roughing mill dari yang sebelumnya 55,88% menjadi 69,42%, mesin finishing mill dari yang sebelumnya 45,82% menjadi 58,20%, mesin laminar cooling dari yang sebelumnya 50,57% menjadi 63,67%, dan mesin down coiler dari yang sebelumnya 50,36% menjadi 65,69%.
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The Hot Strip Mill (HSM) plant is one of the Hot Rolled Coil (HRC) factories which operates under the auspices of PT. Krakatau Steel (Persero) Tbk. In the HRC production process, the HSM plant experienced several problems including defect products that exceeded the maximum target, frequent replacement of engine parts, and sudden engine shutdown. This happens because the HSM plant has six old and running machines in series in the Hot Rolled Coil (HRC) production process, including reheating furnace machines, sizing press, roughing mill, finishing mill, laminar cooling, and down coiler. For this reason, this research will make a process of improvement using the Define-Measure-Analysis-Improve-Control (DMAIC) framework as a reference to improve the HRC production process. By using the availability, performance rate, and quality rate parameters as a measure of the effectiveness of engine performance in the Overall Equipment Effectiveness (OEE) method, the OEE parameters will be broken down into Six Big Losses. Furthermore, the root causes of Six Big Losses are used as input for Failure Mode and Effect Analysis (FMEA) to determine the priority order of problems that occur (critical failure), so that they can be a reference in recommending improvements. Recommendations for improvement are made using the TRIZ Method, which offers the best solution through a new approach by finding a tradeoff behind the problem. The recommended improvement is estimated to be able to increase the OEE value in the reheating furnace machine from 66.34% to 75.65%, sizing press from the previous 52.44% to 66.62%, roughing mill from the previous 55.88% to 69.42%, finishing mill from 45.82% to 58.20%, laminar cooling from 50.57% to 63.67%, and down coiler from 50.36% to 65.69%.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | DMAIC, OEE, Six Big Losses, TRIZ |
| Subjects: | T Technology > TJ Mechanical engineering and machinery T Technology > TS Manufactures T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering) |
| Divisions: | Faculty of Industrial Technology > Industrial Engineering > 26201-(S1) Undergraduate Thesis |
| Depositing User: | Bagas Saestu Adi Putera |
| Date Deposited: | 20 Aug 2020 00:51 |
| Last Modified: | 26 Oct 2023 04:39 |
| URI: | http://repository.its.ac.id/id/eprint/79259 |
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