RANCANGAN MACHINERY FAILURE MODE AND EFFECT ANALYSIS PADA AUTOMATIC SPRAY MACHINE STUDI PADA PT ABC

Levino Mariano, Wakhid Slamet Ciptono, PhD, MBA, MPM

2014 | Tesis | S2 Magister Manajemen

Mesin-mesin yang dipakai untuk melaksanakan proses painting di area Painting#1, PT. ABC pada tahun 2012 mengalami kerusakan sebanyak 4.053 menit, padahal Key Performance Indicator kerusakan yang diberikan oleh manajemen puncak adalah maksimum 2.268 menit. Berdasarkan analisa, 65,08% kerusakan mesin disebabkan karena lemahnya metoda perawatan mesin. Oleh karena itu, untuk mencapai Key Performance Indicator kerusakan tersebut pada tahun 2013, metoda perawatan mesin yang telah diterapkan selama ini perlu diperbaiki, dengan Automatic Spray Machine sebagai pilot project-nya. Metoda perawatan mesin di PT. ABC selalu dikembangkan dengan Root Cause Analysis bila kerusakan mesin terjadi. Walaupun begitu, kerusakan mesin terus terjadi. Sehingga disimpulkan bahwa perlu metoda pengembangan selain Root Cause Analysis. Penelitian ini menggunakan metoda Failure Mode and Effect Analysis yang bersifat proaktif terhadap kerusakan, demi menutupi kekurangan metoda Root Cause Analysis yang bersifat pasif. Setelah rancangan Failure Mode and Effect Analysis pada Automatic Spray Machine selesai disusun, diperoleh hasil bahwa risiko kerusakan saat ini diklasifikasikan sangat besar, yaitu 5.819,71 menit, dimana 2.552,65 menit diidentifikasi sebagai besar risiko yang tidak diketahui dapat terjadi. Besarnya risiko saat ini disebabkan karena keefektifan metoda perawatan yang digunakan diklasifikasikan rendah, yaitu rata-rata detection adalah 7,2. Dengan memperbaiki metoda perawatan, besar risiko kerusakan dapat diturunkan sebesar 84,30%. Tetapi, walau perbaikan metoda perawatan sangat efektif, Key Performance Indicator kerusakan pada tahun 2013 belum bisa dicapai, sehingga perbaikan pada rancangan Automatic Spray Machine juga diperlukan untuk menurunkan risiko yang disebabkan oleh faktor occurrence dan severity. Kata Kunci: Metoda perawatan mesin, kerusakan, root cause analysis, failure mode and effect analysis, besar risiko, detection, occurrence, severity

In 2012, machine breakdown happened for proceeding painting process at Painting#1 area of PT.ABC was 4.053 minutes, while Key Performance Indicator set up by Top Management as standard for machine breakdown is only 2.268 minutes in maximum. Based on analysis, 65,08% machine breakdown was caused by the weakness of machine preventive maintenance, therefore to achieve KPI standard in 2013, the usual method of machine preventive maintenance need to be improved, and Automatic Spray Machine has been chosen as the pilot project. PT. ABC always develops their machine’s preventive maintenance method by using Root Cause Analysis whenever machine breakdown occurred. Nevertheless, machine breakdowns still occur frequently. Therefore, nowadays this study has used Failure Mode and Effect Analysis method as a proactive action to overcome the shortage of Root Cause Analysis method. Result of the Failure Mode and Effect Analysis design implemented on Automatic Spray Machine, the machine breakdown risk is classified very big, reaches until 5.819,71 minutes. From this total risk, 2.552,65 minutes were being identified as major risks that are unknown to occur. Magnitude of the risk were due to the low effectiveness of preventive maintenance method, with averaging detection is 7,2. By improving the preventive maintenance method, the machine breakdown risk could be eliminate to 84,30%. Despite the improvement in preventive maintenance methods, the Key Performance Indicator of machine breakdown in 2013 still could not be achieved, hence improvement in the design of Automatic Spray Machine will also be needed to further eliminate the risks caused by the occurrence and severity factors.

Kata Kunci : Metoda perawatan mesin, kerusakan, root cause analysis, failure mode and effect analysis, besar risiko, detection, occurrence, severity