Perbaikan Proses Produksi Komponen Coal Nozzle Burner Pltu Dengan Menggunakan Lean Manufacturing

Ghiffari, Yanurarzaqa (2021) Perbaikan Proses Produksi Komponen Coal Nozzle Burner Pltu Dengan Menggunakan Lean Manufacturing. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT PLN (Persero) PUSHARLIS UP2W VI Surabaya memproduksi komponen coal nozzle burner dengan penerapan sistem make to order. Adanya fenomena penentuan lead time yang semakin cepat untuk memenuhi kebutuhan emergency repair, maka menuntut produk yang berkualitas dan pengiriman yang tepat waktu pada saat pemeliharaan PLTU. Untuk itu, UP2W berupaya mengelola sistem produksinya secara lebih efektif dan efisien melalui identifikasi aktivitas value added, mereduksi waste dan memperpendek lead time serta proses perbaikan yang berkesinambungan. Berdasarkan observasi awal ditemukan indikasi penyebab waste yaitu sering adanya proses repair, rework, dan delay proses, dimana hal ini merupakan aktivitas yang tidak bernilai tambah.
Penelitian ini menggunakan metode lean manufacturing untuk mengeliminasi 9-waste (E-DOWNTIME). Identifikasi aktivitas yang mengandung pemborosan dilakukan menggunakan value stream mapping dan process activity mapping. Sedangkan lean tool yang digunakan untuk analisis waste lebih lanjut adalah Lean Assessment Matrix (LAM) yang mengintegrasikan House of Risk (HOR) dan Waste Relationship Matrix (WRM). Berdasarkan hasil assessment matrix ini, didapatkan waste kritis yakni waiting, defect dan excess processing. Akar penyebab waste ini adalah karena proses penanganan material dan produk defect belum ditetapkan, kurangnya keterampilam tenaga kerja, dan program 5S belum optimal. Prioritas rekomendasi perbaikan yaitu membuat SOP penanganan material dan produk defect, training dan sertifikasi pekerja pada bagian proses welding, optimalisasi program 5R/5S untuk penanganan material dan peralatan workshop. Hasil eliminasi waste tersebut dapat berkontribusi terhadap penurunan lead time sebesar 20% atau 1605 menit, sehingga tercapainya target ketepatan waktu dalam mendukung kebutuhan komponen coal nozzle burner pada PLTU.
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PT PLN (Persero) PUSHARLIS UP2W VI Surabaya produces coal nozzle burner components by applying a make-to-order system. The phenomenon of determining the lead time that is getting faster to meet the needs of emergency repair requires quality products and on-time delivery when maintaining the PLTU. For this reason, UP2W strives to manage its production system more effectively and efficiently by identifying value-added activities, reducing waste, and shortening lead times as well as a continuous improvement process. Based on preliminary observations, an indication of the causes of waste is found, namely the frequent repair, rework, and process delays, where these are non-value-added activities.
This study uses lean manufacturing methods to eliminate 9-waste (E-DOWNTIME). The identification of activities that contain waste is carried out using value stream mapping and process activity mapping. Meanwhile, the lean tool used for further waste analysis is the Lean Assessment Matrix (LAM) which integrates the House of Risk (HOR) and the Waste Relationship Matrix (WRM). Based on the results of this assessment matrix, critical waste is obtained, namely waiting, defects, and excess processing. The root cause of this waste is because the process of handling material and defective products has not been determined, the lack of skills in the workforce, and the 5S program is not yet optimal. The priority recommendations for improvement are making SOPs for handling material and defect products, training and certifying workers in the welding process, optimizing the 5R / 5S program for material handling and workshop equipment. The results of waste elimination can contribute to a reduction in lead time by 20% or 1605 minutes so that the target timeliness is achieved in supporting the needs of the coal nozzle burner component at the PLTU.

Item Type:	Thesis (Masters)
Additional Information:	Beberapa data penelitian terkait dengan data terbatas perusahaan
Uncontrolled Keywords:	coal nozzle burner, e-downtime, lean manufacturing, VSM, PAM, lean assessment matrix
Subjects:	T Technology > T Technology (General) > T56.8 Project Management T Technology > TJ Mechanical engineering and machinery > TJ164 Power plants--Design and construction T Technology > TJ Mechanical engineering and machinery > TJ263.5 Boilers (general) T Technology > TS Manufactures > TS155 Production control. Production planning. Production management T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions:	Faculty of Creative Design and Digital Business (CREABIZ) > Technology Management > 61101-(S2) Master Thesis
Depositing User:	Yanurarzaqa Ghiffari
Date Deposited:	24 Feb 2021 03:05
Last Modified:	24 Feb 2021 03:06
URI:	http://repository.its.ac.id/id/eprint/82735

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