20 research outputs found
Peningkatan Mutu Proses Pembuatan Cat Solvent dengan Metode Taguchi di PT JI
No full textIn a manufacturing process, quality is not only seen from the final product, but also manufacturing process. PT JI located in Cikarang is a company that produces paints and powder coating. Currently, the company has problems with 24.16% products that need rework or additional process. To increase productivity, PT JI applies the A3 project that is Right First Time (RFT). RFT is how to create a product with a one-time process and produce a product that has good quality on the first test. The average percentage of total RFT products in September 2016-January 2017 was 75.84%. This result is still below the company target of 80%. This study found the source of problems analyzed the manufacturing process using control chart, process capability, fishbone, and pareto. Taguchi method and ANOVA are applied to improve the design process. The application of the Taguchi Method shows that the factors which influence the value of viscosity quality are number of White Spirit, Number of Genekyd, Total Tio2 (kaolin), and mixing temperature, where each factor has an optimal level of 26.01%, 56.07%, 18.78% and 45oC. Then, it is found that all control factors have significant effect on viscosity value from ANOVA analysis. The application of this Taguchi method increases the process capability to Cp = 1.68 and Cpk = 1.43 from Cp = 0.29 and Cpk = 0.18, as well as an increase in RFT percentage of 5.78% or to 81.62% over the last two months
ANALISIS JAM KERJA EFEKTIF DALAM UPAYA PENINGKATAN PRODUKTIVITAS TENAGA KERJA DENGAN METODE PDCA DI PT NMI
No full textAdanya persaingan yang sangat ketat di pasar menuntut produsen untuk melakukan perbaikan secara terus menerus untuk menghasilkan produk dengan kualitas terbaik dan harga paling kompetitif. Hal tersebut merupakan suatu kewajiban yang tidak terhindarkan agar perusahaan mampu bertahan. PT NMI adalah produsen pedestal yang menganut sistem job order. Dalam usaha untuk meningkatkan daya saing karena meningkatnya tuntutan pelanggan, perusahaan ini memiliki kendala yang berkaitan dengan ketepatan waktu pengiriman. Hasil observasi yang dilakukan menunjukkan bahwa penyebabnya adalah utilisasi jam kerja yang masih rendah yaitu hanya 68,7%. Penelitian ini bertujuan untuk mencari cara agar utilisasi dapat ditingkatkan sehingga kepastian waktu pengiriman menjadi lebih baik. Metodologi yang digunakan adalah analisis jam kerja efektif pada PT. NMI dengan menggunakan metode Plan-Do-Check-Act (PDCA). Pendekatan dilakukan dengan mengidentifikasi cara menaikkan utilisasi jam kerja agar dapat meningkatkan kapasitas produksi pedestal dengan memperhatikan produktivitas dan jumlah karyawan sehingga dapat memenuhi permintaan pelanggan dengan tepat waktu. Penerapan PDCA menghasilkan solusi bahwa upaya meningkatkan jam kerja efektif dapat dilakukan dengan merubah standard raw material yang digunakan dan standard kerja produksi. Setelah dilakukan perubahan standard raw material dan penggunaan standard kerja produksi yang baru, diperoleh hasil pemakaian jam kerja mengalami peningkatan dari 68,7% menjadi 82,4% dan produktivitas tenaga kerja meningkat dari 41 pcs/jam menjadi 52 pcs/jam
Perbaikan Pengelolaan Pergudangan Melalui Penerapan Sistem Informasi Pergudangan di CV. ABB
No full textCV ABB is a medium scale car rental company which manages around 150 vehicles consists of small car (sedan or MPV) until large bus. To supporting the maintenance of all vehicles, they build a warehouse for spareparts and tools. Unfortunately, the management of warehouse does not have a good governance because all records done manually. This situation creates very high risk for data manipulation because manual record method is done by warehouse officer, lost of spare part in warehouse, counterfeit receipt, and no system to control spare part in warehouse. An improvement need to be done by implementing a warehouse management information system to overcome this problem. By applying information system analysis and design concepts and implementing through the application of PHP7 and MySQL, the new system can control all spare part in warehouse including incoming and outgoing spare part, PIC who requests the spare part, checking stock of spare part in the warehouse and stock out used by finance to make purchase order, spare part report from supplier and spare part request report. This system is also able to help finance to create purchase order and get approval from the user in order to make the process is more transparent and accountable
Perbaikan Sistem Kerja Proses Pemasangan Ban Truk dengan Perancangan Peralatan Pendukung Menggunakan QFD dan REBA
No full textPT.X as one of the heavy equipment manufacturing company are producing mining and non-mining transportation product (e.g. Semi Side Tipper (SST) & Dolly). In producing those kinds of products that mostly using tires, there is a process area to do mounting truck tire. Based on interviews and direct observation results, there is a symptom of Cumulative Trauma Disorders (CTD), especially in the low back area. The low back pain experienced by the operators is caused by an awkward posture that resulted from Manual Material Handling (MMH) in this process. Lifting and holding the tire that is located on the floor with diameter 1.2m, height 0.3m, and weight 90 Kg also the reasons why the awkward posture appears during the mounting truck tire process. Using Rapid Entire Body Assessment (REBA), Nordic Questionnaire, and followed by the Quality Function Deployment (QFD) approach for product design are used to do the improvement for the process. In the end, these ergonomics issues are solved by developing material handling tools that can minimize the risk and symptoms of CTDs. It can be shown by initially REBA score is on level 11 (Very High Risk) to level 7 (Medium Risk) and for the Nordic result from 7 body parts that feel discomfort, now it just becomes 1 body parts feel discomfort
Manajemen Perawatan Menggunakan Metode RCM Pada Mesin Produksi Kertas
No full textOne of the leading manufacturers in packaging paper in Indonesia has six production machines. To keep the production machine always in the best condition, then the role of maintenance is significant. One of the production machines, namely paper production machine 2 (PM2), has experienced increasing the number of breakdowns significantly, resulting in increased downtimes. Sudden failure causes a lengthy repair time and results in considerable production loss. The corrective maintenance method that is running at this time still not effectively reduce downtime. To minimize the number of downtimes, preventive maintenance is needed, and therefore the Reliability Centered Maintenance (RCM) method is selected. Besides applying quantitative analysis such as Mean Time To Repair (MTTR), Mean Time To Failure (MTTF), reliability, and preventive cost calculations. This method also conducts qualitative analysis such as Functional Block Diagrams (FBD), critical engine analysis, Fault Tree Analysis (FTA), and Failure and Mode Effect Analysis (FMEA). After implementing the preventive maintenance, there is an increase in reliability in the sub-system of the press section of the paper production machine 2 from only 43% to 56%, while the repair cost has been reduced by Rp 393,258,670 from Rp 5,724,825,736 to Rp 5,331,567,066 each time replacement of components in the press section. This decrease in costs will contribute to the profits earned by the company because it saves maintenance costs
PENGENDALIAN PERSEDIAAN DAN PENJADWALAN PASOKAN BAHAN BAKU IMPORT DENGAN METODE ABC ANALYSIS DI PT UNILEVER INDONESIA, CIKARANG, JAWA BARAT
No full textInventory control becomes a very important activity in a company because the cost of inventory can reach about 20% to 40% of the total annual value. Inventory is a capital or company asset consist of raw materials, work in process and finished product. Currently, the value of inventory at PT Unilever Indonesia Savory Factory has exceeded the maximum target of the company but some raw materials have shortage or stock-out, meaning that the current inventory condition is inefficient because the company invests too much in inventory but the shortage of inventory for certain raw materials still occurs. This is the reason why it is necessary to improve inventory efficiency. Improvements were made by utilizing ABC inventory analysis method and arranging and scheduling raw material supply as needed, then making priority scale of raw material improvement on ABC inventory analysis based on class A, B and C. The research was continued by rescheduling the tracking delivery and counting time frozen horizon which is the amount of time it takes raw materials during the distribution process or delivery process, so the frozen horizon is smaller than lead time. By performing fixed order interval on class A and fixed order quantity raw materials for class B and C raw materials, the quantity of imported raw materials gradually adjust to the needs and the high value of the company’s inventory can be reduced gradually as well. The end result is the risk of shortage can be reduced as much as 26%, overstock can be reduced by 12% and in total overall value over value inventory can be decreased as much as 23%.Pengendalian inventory menjadi aktivitas yang sangat penting pada sebuah perusahaan karena biaya inventory dapat mencapai sekitar 20% hingga 40% dari total nilai tahunan. Persediaan merupakan modal atau aset perusahaan berupa raw materials, work in process, dan finished product. Saat ini, nilai inventory di PT Unilever Indonesia Savoury Factory sudah melebihi target maksimum perusahaan. Namun, beberapa bahan baku mengalami shortage atau stock-out, artinya kondisi inventory saat ini tidak efisien karena perusahaan menanamkan terlalu banyak dana dalam persediaan namun kekurangan persediaan untuk bahan baku tertentu tetap terjadi. Hal ini menjadi alasan mengapa perlu dilakukan perbaikan efisiensi inventory. Perbaikan dilakukan dengan memanfaatkan metode analisis ABC persediaan dan melakukan pengaturan dan penjadwalan pasokan bahan baku sesuai kebutuhan, kemudian membuat skala prioritas perbaikan bahan baku pada analisis ABC persediaan berdasarkan kelas A, B, dan C. Penelitian dilanjutkan dengan melakukan rescheduling dengan melakukan tracking delivery dan menghitung waktu frozen horizon yaitu jumlah waktu yang dibutuhkan bahan baku selama proses distribusi atau proses delivery, sehingga frozen horizon lebih kecil dari lead time. Dengan melakukan fixed order interval pada bahan baku kelas A dan fixed order quantity untuk bahan baku kelas B dan C, maka kuantitas bahan baku impor secara bertahap menyesuaikan dengan kebutuhan dan tingginya nilai inventory perusahaan dapat dikurangi secara bertahap pula. Hasil akhirnya adalah risiko shortage dapat dikurangi sebanyak 26%, overstock dapat dikurangi sebesar 12%, dan secara total keseluruhan value over value inventory dapat diturunkan sebanyak 23%
Implementasi Line Balancing untuk Peningkatan Efisiensi di Line Welding Studi Kasus: PT X
No full text<p><em>Line balancing is a jobs assignment into a number of work stations that are interrelated in a track or a production line with an objective to minimizing the idle time on the line that is determined by the slowest operation. In line welding 1DY models includes eight work stations where one work station is done by one operator. Problems have been found that these operators have very long idle time and also there is too much wip that creates bottleneck in the production line so these leads to a waste of manpower and time. This waste of manpower and time need to be reduced by determining the optimal amount of labor in order to avoid excessive idle time but work can be done effectively and efficiently. One way to adress imbalance line is to apply line balancing methods.The results of this research shows that the line balancing methods can reduced the waste of time and give solutions for the optimal amount of labor requirements for line welding 1DY models.</em></p><p>Keywords: Line Balancing, Workstation, Production Line, Idle Time, Bottleneck.</p><p><em><br /></em></p></jats:p
Perencanaan Perawatan Pada Unit Kompresor Tipe Screw Dengan Metode RCM di Industri Otomotif
No full textProduction process at PT. Showa Indonesia Manufacturing is not always smooth, due to the ignorance of the reliability of the machine. Breakdown can occur at any time and cause uncertainty of the availability of machinery in the production process, causing considerable losses to the company. This study was conducted on a compressor machine used to produce the pressurized air that used to run the production machinery. Based on the research, the highest damage level is on the compressor machine 4, 8, 10, 5, 16, and 6 with total damage of 70.1%. This is due to the complex machine system and the less optimal maintenance system. Reliability Centered Maintenance (RCM) method is used to analyze the system to identify components that fall within the critical category. The results of the analysis, obtained some critical components which required optimal replacement interval by minimizing downtime. Further planning activities on each critical component is based on FMEA and RCM Decision Worksheet. With the application of RCM method, total downtime decreased by 44.59% from previous preventive actions
Peningkatan Efisiensi Tempat Penyimpanan Dokumen dengan Menggunakan Metode 5S dan Siklus PDCA di Industri Farmasi
No full textPusat penelitian dan pengembangan obat yang ada di PT Dexa Medica adalah Dexa Development Center (DDC). Output dari DDC adalah dokumen dan disimpan dalam tempat penyimpanan yang dinamakan Kardex Remstar Shuttle XP 500. Pada periode 2019 - 2020 ditemukan penumpukkan dokumen di dalam kardex sebesar 4529 ordner, area kosong yang tersisa 171, diluar kardex 550 ordner, ruang tempat penyimpanan menjadi tidak rapi, membutuhkan waktu yang lama saat mencari dokumen, tidak ada penambahan area dan sistem pengelolaan dokumen belum dilakukan proses pemusnahan. Dengan adanya masalah tersebut dilakukan perbaikan dengan analisis siklus PDCA dan 5S sebagai langkah yang dilakukan pada do. Hasil dari analisis siklus PDCA adalah dokumen di dalam kardex berkurang dari 290 ordner terdapat 45 ordner atau 16% musnah, area kosong meningkat dari 171 menjadi 216 ordner atau 21% dan secara total meningkat dari 4529 menjadi 4908 atau 104%. Jumlah ordner di luar kardex berkurang dari 550 menjadi 126 ordner atau 77,09%. Dengan penggantian ordner menghemat biaya sebesar Rp 5.168.160 atau 79,90%. Menghemat waktu pencarian dokumen di luar kardex dari 510 detik menjadi 33 detik atau 94%. Pengelolaan dokumen agar tetap dijalankan supaya tidak terjadi penumpukan dan tempat penyimpanan dapat dimanfaatkan secara optimal
IMPLEMENTING AN AUTOMATED SYSTEM TO SIMPLIFY THE DATA MANAGEMENT PROCESS AT PARTS STORAGE AREA OF PT. Z
No full textThis research concerns about the design and implementation of a new information system which will simplify the processes of the current system and its impact on the warehouse staffs. In order to automate the processes, a programmed information system is designed using Microsoft excel VBA, a basic programming function inside Microsoft excel. First, the current system is analyzed. Next, the user requirements and proposed system requirements are analyzed to make the system design. Then, the program is developed and tested by using VBA (Visual Basic for Applications). Then, the new system is implemented and the implementation results are analyzed. The results found that the new system successfully fulfilled the objectives of this research and the user requirements, although there are still some improvements which need to be done. During two months’ period of implementation, there are some problems encountered which required the programmer to improve the system. Like every system, there are some advantages and disadvantages found in this new system.
Abstrak
Penelitian ini fokus kepada desain dan implementasi sistem informasi baru yang akan mengotomatisasi proses dari sistem saat ini dan dampaknya terhadap staf gudang. Dalam rangka untuk mengotomatisasi proses, sistem informasi yang terprogram dirancang menggunakan Microsoft excel VBA,sebuah fungsi dasar pemrograman dalam Microsoft excel. Pertama, sistem yang sekarang dianalisis. Selanjutnya, kebutuhan pengguna dan kebutuhan sistem yang diusulkan dianalisis untuk membuat desain sistem. Kemudian, program ini dikembangkan dan diuji dengan menggunakan VBA (Visual Basic for Applications). Kemudian, sistem baru diimplementasikan dan hasil dari implementasi dianalisis. Hasil penelitian menemukan bahwa sistem baru berhasil memenuhi tujuan penelitian ini dan kebutuhan pengguna, meskipun masih ada beberapa perbaikan yang perlu dilakukan. Selama periode dua bulan implementasi, ada beberapa masalah yang dihadapi yang membutuhkan programmer untuk mengembangkan sistemnya. Seperti setiap sistem, ada beberapa kelebihan dan kekurangan yang ditemukan dalam sistem baru ini
