USULAN PERBAIKAN PROSES PRODUKSI SHOULDER FOR ECLIP DENGAN METODE WASTE ASSESSMENT MODEL

Abstract

Abstrak

Sebagai perusahaan yang bergerak di bidang manufaktur, PT Pindad (Persero) tentunya perlu memperhatikan aspek efisiensi mulai dari proses produksi hingga produk jadi dapat sampai di tangan konsumen, tidak terkecuali pada produk Shoulder For E-Clip. Berdasarkan studi dan observasi yang dilakukan, ditemukan tujuh jenis waste yang terjadi di sepanjang proses produksi Shoulder For E-Clip. Identifikasi dan pemeringkatan waste dilakukan dengan menggunakan metode Waste Assessment Model (WAM). Hasil pengolahan data menunjukkan bahwa waste paling kritis ditemukan pada jenis overproduction dengan persentase 20.71%, diikuti defects dengan persentase 18.77%, serta inventory dengan persentase 15.71%. Sub-waste dari ketiga waste paling kritis dicari menggunakan analisis 5-Whys sebagai bahan pertimbangan untuk mencari akar permasalahan pada metode Failure Mode and Effect Analysis (FMEA). Hasil analisis pada FMEA menunjukkan bahwa Risk Priority Number (RPN) tertinggi ditemukan pada mode kegagalan breakdown mesin akibat produksi yang melebihi kapasitas, produk tidak sesuai spesifikasi akibat proses penuangan yang hanya mengandalkan feeling operator, serta penumpukan bahan mentah akibat kehabisan bahan bakar. Usulan perbaikan yang diberikan berupa pengadaan training berkala tentang maintenance mesin kepada operator, melakukan reverse engineering pada mesin sambil meningkatkan pengawasan, serta melakukan evaluasi atau pergantian pada vendor penyedia bahan bakar.

Kata kunci: 5-Whys; FMEA; Proses produksi; RPN; Shoulder for E-Clip; Waste Assessment Model

Abstract

As a manufacturing company, PT Pindad (Persero) needs to pay attention to production process efficiency until the finished products can reach consumers, including Shoulder For E-Clip products. Based on studies and observations conducted, seven types of waste were found that occurred throughout the Shoulder For E-Clip production process. Waste identification and ranking is done using the Waste Assessment Model (WAM) method. The data processing results showed that the most critical wastes were Overproduction with a percentage of 20.71%, followed by Defects with a percentage of 18.77%, and Inventory with a percentage of 15.71%. Sub-waste of the three most critical wastes is sought using 5-Whys analysis as a consideration to find the root cause in the Failure Mode and Effect Analysis (FMEA) method. FMEA results showed that the highest Risk Priority Number (RPN) was found in the engine breakdown failure mode due to production that exceeded capacity, the product did not meet specifications due to the inaccurate pouring process, as well as the cummulation of raw materials due to fuel shortage. The proposed improvements provided are conducting periodic training on engine maintenance for operators, reverse engineering on the engine while increasing supervision, and evaluating or replacing fuel suppliers. Keywords: 5-Whys; FMEA; Production process; RPN; Shoulder for E-Clip; Waste Assessment Model