Improvement Of Overhead Crane Machine Maintenance Activities Using Lean Maintenance Approach On PT Adhi Persada Beton

Humam, Misbah Choirul (2022) Improvement Of Overhead Crane Machine Maintenance Activities Using Lean Maintenance Approach On PT Adhi Persada Beton. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT Adhi Persada Beton is a manufacturing company in the precast concrete sector. One of the products that have highest demand is spun pile which is produced in Shelters 1 & 2. PT Adhi Persada Beton has problems with maintenance where overhead crane machines at shelters 1 & 2 frequent downtime. This study aims to reduce downtime on overhead crane machines 001, 002, 003, 004, 005 and 019 and eliminate waste that occurs in maintenance activities using lean maintenance approach. This research begins with the identification of the existing conditions on the overhead crane and maintenance. Then visualization of maintenance is performed using Value Stream Maintenance Mapping (VSMM). Based on the VSMM visualization, the Mean Maintenance Lead Time (MMLT) was 102 minutes with 59% value added activity, 3% non-value added, and 38% necessary non-value added. Furthermore, analysis of other parameters such as Overall Equipment Effectiveness (OEE), measurement of MTBF and MTTR as well as looking for critical maintenance waste using Fault Tree Analysis (FTA). The average OEE value for each of existing overhead crane machines is 70%, which is still under value the world-class standard of 85%. The gap that occurs is due to the low availability rate and performance rate of overhead cranes. From the results of the study, it was found that waste that occurs in maintenance is centralized maintenance, unnecessary movements, poor inventory management, poor maintenance, less resource utilization, ineffective data management, unproductive maintenance, and waiting for maintenance resources. The root causes for each waste are there isn't any routine training and skill mapping standards from the company, spare parts that are not arranged in the workshop, no recording when picking up items, spare parts are difficult to find on the market, and there is no admin for recapitulation of maintenance data and repair. So that in the research proposed several recommendations for improvement. The selected improvement recommendations include training on overhead crane maintenance and repair skills, implementation of 5S in the workshop area, and autonomous maintenance by operators. Recommendations regarding preventive maintenance scheduling are based on the calculation of the maintenance interval of each overhead crane machine.
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PT Adhi Persada Beton merupakan perusahaan manufaktur di bidang beton precast. Salah satu produk dengan demand paling tinggi adalah spun pile yang diproduksi pada Shelter 1 & 2. PT Adhi Persada Beton memiliki permasalahan pada aktivitas pemeliharaan dimana mesin overhead crane pada shelter 1 & 2 sering mengalami downtime. Penelitian ini bertujuan untuk mengurangi downtime pada mesin overhead crane 001, 002, 003, 004, 005 dan 019 serta mengeliminasi waste yang terjadi pada aktivitas pemeliharaan menggunakan pendekatan lean maintenance. Penelitian ini dimulai dengan mengidentifikasi kondisi eksisting pada overhead crane dan aktivitas pemeliharaan. Kemudian dilakukan visualisasi aktivitas pemeliharaan menggunakan Value Stream Maintenance Mapping (VSMM). Berdasarkan hasil visualisasi VSMM didapatkan waktu Mean Maintenance Lead Time (MMLT) selama 102 menit dengan jenis aktivitas value added sebesar 59%, non-value added sebesar 3%, dan necessary non-value added sebesar 38%. Selanjutnya dilakukan analisis parameter lain seperti perhitungan Overall Equipment Effectiveness (OEE), pengukuran MTBF dan MTTR serta identifikasi maintenance waste kritis menggunakan Fault Tree Analysis (FTA). Nilai rata-rata OEE pada masing-masing mesin overhead crane eksisting sebesar 70% dimana masih dibawah nilai standar world class yaitu sebesar 85%. Gap yang terjadi karena rendahnya nilai availability rate dan performance rate pada overhead crane. Dari hasil penelitian didapatkan waste yang terjadi pada aktivitas pemeliharaan yaitu centralized maintenance, unnecessary motion, poor inventory management, poor maintenance, under-utilization of resource, ineffective data management, unproductive maintenance, dan waiting for maintenance resources. Akar penyebab pada masing-masing waste adalah belum adanya training rutin dan standar skill mapping dari perusahaan, spare part yang tidak tertata di workshop, tidak ada pencatatan ketika pengambilan item, spare part sulit ditemukan di pasaran, serta tidak ada admin untuk rekapitulasi data pemeliharaan dan perbaikan. Sehingga pada penelitian diusulkan beberapa rekomendasi perbaikan. Rekomendasi perbaikan yang terpilih diantaranya training skill pemeliharaan dan perbaikan overhead crane, implementasi 5S pada area workshop, dan autonomous maintenance oleh operator. Rekomendasi perbaikan terkait penjadwalan preventive maintenance dilakukan berdasarkan perhitungan interval maintenance dari keandalan setiap mesin overhead crane.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Lean Maintenance, Overall Equipment Effectiveness, Value Stream Mapping, Maintenance Waste Kritis, Lean Maintenance, Overall Equipment Effectiveness, Value Flow Mapping, Critical Maintenance Waste
Subjects:	T Technology > T Technology (General) > T174.5 Technology--Risk assessment. T Technology > T Technology (General) > T55 Industrial Safety
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	19 Feb 2026 01:41
Last Modified:	19 Feb 2026 01:41
URI:	http://repository.its.ac.id/id/eprint/132508

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