LEAN MAINTENANCE PADA TRANSMISSION CASE TD LINE UNTUK MEREDUKSI WASTE GUNA MENINGKATKAN EFEKTIVITAS DAN EFISIENSI PERAWATAN MESIN DI PT MITSUBISHI KRAMA YUDHA MOTORS & MANUFACTURING

Abstract

Abstrak

PT Mitsubishi Krama Yudha Motors and Manufacturing (PT MKM) adalah perusahaan otomotif Indonesia - Jepang yang membuat komponen mesin dan body kendaraan niaga (mobil pick-up dan truk) dengan merk Mitsubishi. PT MKM memproduksi berdasarkan jumlah pesanan yang diterima dari distributor tunggal kendaraan Mitsubishi di Indonesia yaitu PT Krama Yudha Tiga Berlian (KTB). PT MKM sering mengalami masalah mesin breakdown. Adanya mesin breakdown menyebabkan proses produksi terhenti dan target harian produksi tidak tercapai. Makin lama proses perbaikan mesin menyebabkan produktivitas menurun. Berdasarkan data historis breakwon mesin perusahaan tahun 2021 didapatkan bahwa pada Transmission Case TD Line sering mengalami breakdwon. Oleh karena itu, perlu identifikasi waste pada proses perbaikan mesin di Transmission Case TD untuk meningkatkan efektivitas dan efisiensi perbaikan mesin. Penelitian ini menggunakan konsep lean maintenance yang dapat mereduksi waste maintenance. Selain itu, juga dilakukan perhitungan efektivitas mesin dengan Mean Time Between Failure (MTBF) dan Mean Time To Repair (MTTR). Aktivitas perbaikan mesin akan digambarkan dengan Maintenance Value Stream Mapping (MVSM) dan dilakukan identifikasi waste serta perhitungan efisiensinya. Berdasarkan hasil penelitian, mesin yang paling sering mengalami breakdown adalah TM-10. Penyebab kerusakan terbesar karena part yang rusak sebesar 49%. Nilai efisiensi sebelum perbaikan 27,93% dan sesudah perbaikan menjadi 41,67%.

Kata kunci: Lean Maintenance, MTBF, MTTR, RCA.

Abstract

PT Mitsubishi Krama Yudha Motors and Manufacturing (PT MKM) is an Indonesian-Japanese automotive company that makes engine and body components for commercial vehicles (pick-ups and trucks) under the Mitsubishi brand. PT MKM produces based on the number of orders received from the sole distributor of Mitsubishi vehicles in Indonesia, PT Krama Yudha Tiga Berlian (KTB). PT MKM often experiences engine breakdown problems. The existence of machine breakdowns causes the production process to stop and the daily production target is not achieved. The longer the machine repair process takes, the lower the productivity. Based on the historical data of the company's machine breakwon in 2021, it is found that the Transmission Case TD Line often experiences breakdwon. Therefore, it is necessary to identify waste in the engine repair process at Transmission Case TD to increase the effectiveness and efficiency of engine repair. This research uses the concept of lean maintenance which can reduce maintenance waste. In addition, the calculation of machine effectiveness with Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR) is also carried out. Machine repair activities will be described with Maintenance Value Stream Mapping (MVSM) and waste identification and efficiency calculations are carried out. Based on the research results, the machine that most often experiences breakdowns is TM-10. The biggest cause of breakdown is due to broken parts at 49%. The efficiency value before improvement is 27.93% and after improvement is 41.67%.

Keywords: Lean Maintenance, MTBF, MTTR, RCA