Penerapan Metode Lean Maintenance Pada Pemeliharaan Mesin Lathe Untuk Meningkatkan OEE (Studi Kasus: CV.XYZ)

Anugera, Akhdan Hafizh (2023) Penerapan Metode Lean Maintenance Pada Pemeliharaan Mesin Lathe Untuk Meningkatkan OEE (Studi Kasus: CV.XYZ). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

CV. XYZ merupakan perusahaan manufaktur yang memproduksi roller conveyor dan flange serta repair spare part otomotif. Salah satu mesin utama pada CV. XYZ adalah mesin lathe yang berfungsi untuk memproses raw material stainless steel silinder menjadi produk jadi. CV. XYZ memiliki permasalahan pada pemeliharaan mesin lathe yang sering mengalami breakdown yang mengakibatkan efektivitas mesin menurun. Downtime yang tinggi dapat menimbulkan waste berupa availabilitas mesin berkurang, waktu tunggu produksi bertambah. Penelitian ini bertujuan untuk mengatasi permasalahan pada pemeliharaan dalam rangka meningkatkan nilai OEE pada mesin lathe serta mengeliminasi waste yang terjadi pada aktivitas pemeliharaan dengan menggunakan pendekatan lean maintenance. Penelitian ini dimulai dengan mengidentifikasi kondisi eksisting mesin lathe dan kegiatan pemeliharaan. CV. XYZ saat ini menerapkan pemeliharaan berupa breakdown maintenance. Selanjutnya menggambarkan aktivitas pemeliharaan menggunakan Value Stream Maintenance Mapping (VSMM). Berdasarkan hasil penggambaran VSMM diperoleh waktu Mean Maintenance Lead Time (MMLT) selama 305 menit dengan klasifikasi aktivitas value added sebesar 56%, necessary non - value added sebesar 44% dan non - value added sebesar 0%. Berikutnya, dilakukan pengukuran berupa MTBF, MTTR, dan Overall Equipment Effectiveness. Rata - rata nilai OEE mesin lathe eksisting sebesar 57%, dimana masih dibawah nilai standar world class sebesar 85%. Gap ini disebabkan oleh rendahnya nilai availability rate dan performance rate pada mesin lathe. Selanjutnya melakukan analisis kondisi eksisting, dilanjutkan dengan analisis six big losses dan maintenance waste menggunakan Root Cause Analysis (RCA) untuk mendapatkan akar permasalahan. Dari hasil penentuan maintenance waste kritis berdasarkan diagram Pareto yaitu poor maintenance, poor inventory management, ineffective data management, waiting for maintenance resources dan under-utilization of resources. Selain itu, hasil penentuan six big losses kritis berupa idling and minor stoppage, equipment failure dan reduced speed. Rekomendasi perbaikan yang terpilih diantaranya penjadwalan preventive maintenance berdasarkan interval maintenance, implementasi 5S pada area kerja, training skill pemeliharaan dan perbaikan mesin lathe dan alur dokumentasi maintenance.
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CV. XYZ is a manufacturing company that produces conveyor rollers and flanges and repairs automotive spare parts. One of the main engines on the CV. XYZ is a lathe machine whose function that process cylindrical stainless steel raw materials into finished products. CV. XYZ has problems with lathe machine maintenance which often experiences breakdowns that result in decreased machine effectiveness. High downtime can cause waste in the form of reduced machine availability, and increased production waiting time. This study aims to overcome problems in maintenance to increase the OEE value on the lathe machine and eliminate waste that occurs in maintenance activities using a lean maintenance approach. This research begins by identifying the existing condition of the lathe machine and its maintenance activities. CV. XYZ is currently implementing maintenance in the form of breakdown maintenance. Next describes maintenance activities using Value Stream Maintenance Mapping (VSMM). Based on the results of the VSMM depiction, it was obtained that the Mean Maintenance Lead Time (MMLT) is 305 minutes on the classification of value-added activities of 56%, necessary non-value added of 44%, and non-value added of 0%. Next, measurements were in the form of MTBF, MTTR, and Overall Equipment Effectiveness. The average OEE value of existing lathe machines is 57%, which is still below the world-class standard value of 85%. This gap is caused by the low value of the availability rate and performance rate on the lathe machine. Then analyze the existing conditions, followed by an analysis six losses and maintenance waste using Root Cause Analysis (RCA) to get to the root of the problem. The results of determining critical maintenance waste based on the Pareto diagrams are poor maintenance, poor inventory management, ineffective data management, waiting for maintenance resources, and under-utilization of resources. In addition, the results of determining the six critical losses are idling and minor stoppage, equipment failure, and reduced speed. The selected improvement recommendations include scheduling preventive maintenance based on maintenance intervals, implementing 5S in the work area, training skills for maintenance and repair of lathe machines, and flow of maintenance documentation.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Overall Equipment Effectiveness, Lean Maintenance, Value Stream Mapping, Root Cause Analysis, Six Big Losses.
Subjects:	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:	Akhdan Hafizh Anugera
Date Deposited:	10 Feb 2023 15:17
Last Modified:	10 Feb 2023 15:17
URI:	http://repository.its.ac.id/id/eprint/96820

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