DETAIL KOLEKSI

Usulan penerapan total productive maintenance pada proses produksi leverassy parking brake 46210-oko40 toyota innova di PT. Nusa Toyotetsu Corporation


Oleh : Desak Putu Wulan Partami

Info Katalog

Penerbit : FTI - Usakti

Kota Terbit : Jakarta

Tahun Terbit : 2008

Pembimbing 1 : Amal Witonohadi

Pembimbing 2 : Tien Gustina Amran

Subyek : Machinery in the workplace - maintenance and repair;Total productive maintenance

Kata Kunci : total productive maintenance, production process, parking brake lever assembly, 46210-oko40, Toyota

Status Posting : Published

Status : Tidak Lengkap


File Repositori
No. Nama File Hal. Link
1. 2008_TA_STI_06303160_Halaman-Judul.pdf 27
2. 2008_TA_STI_06303160_Lembar-Pengesahan.pdf 3
3. 2008_TA_STI_06303160_Bab_1_Pendahuluan.pdf 5
4. 2008_TA_STI_06303160_Bab_2_Landasan-Teori.pdf
5. 2008_TA_STI_06303160_Bab_3_Metodologi-Penelitian.pdf
6. 2008_TA_STI_06303160_Bab_4_Pengumpulan-Dan-Pengolahan-Data.pdf
7. 2008_TA_STI_06303160_Bab_5_Implementasi-Total-Productive.pdf
8. 2008_TA_STI_06303160_Bab_6_Analisa.pdf
9. 2008_TA_STI_06303160_Bab_7_Kesimpulan-dan-Saran.pdf 3
10. 2008_TA_STI_06303160_Daftar-Pustaka.pdf 1
11. 2008_TA_STI_06303160_Lampiran.pdf

P PT. Nusa Toyotetsu Corporation adalah perusahaan yang bergerak dibidang industri komponen otomotif. Produk yang dihasilkan terdiri dari berbagai macam komponen mobil, dan salah satunya adalah lever assy parking brake 46210-0k040 atau sering disebut rem tangan innova. Beberapa masalah yang ada antara lain adalah tidak adanya jadwal perawatan mesin tetap karena selama ini mesin produksi bare akan mendapat perawatan setelah terjadi kerusakan. Selain itu minimnya pengetahuan operator tentang perawatan mesin menyebabkan ketidakteraturan dalam lapangan, karena mereka berpikir hal tersebut merupakan tanggung jawab bagian maintenance. Masalah yang paling utama adalah sering terjadi kerusakan mesin sehingga mengakibatkan efektifitas mesin menurun sehingga merugikan perusahaan. Tahapan awal dilakukan dengan menentukan mesin kritis dengan diagram pareto yang memiliki persentase kumulatif >80%, sehingga didapat 5 mesin kritis yaitu mesin SSW-1, mesin shearing, mesin SSW-2, mesin adhesi dan mesin stamping (GANG 2) lever parking brake L/ cable. Langkah berikutnya adalah menentukan komponen kritis dari masing-masing mesin kritis tersebut dengan diagram pareto yang memiliki persentase kumulatif >80%, dan diperoleh 12 komponen kritis. Dilanjutkan dengan menentukan distribusi berdasarkan least square curve fitting terhadap semua komponen kritis dari data kerusakan dan data perbaikan. Kemudian diuji lagi dengan uji-uji khusus untuk masing-masing distribusi terpilih sesuai dengan index offit terbesar, lalu dilakukan perhitungan parameter, mean time to failure dan mean time to repair, dengan metode maximum likelihood estimator, yang bertujuan untuk menentukan interval waktu penggantian pencegahan dan interval waktu pemeriksaan. Dari perhitungan interval waktu penggantian pencegahan dapat diperoleh nilai availability. Dengan adanya kegiatan perawatan pencegahan maka terjadi peningkatan reliability. Tahap selanjutnya adalah penentuan nilai efektifitas mesin dengan menghitung overall equipment effectiveness (OEE) dengan urutan perhitungan total available time, planned downtime, running time, equipment utilization, setup and adjustment, operating time, planned availability, unplanned downtime, net operating time, uptime, availability, total and good product, rate of quality, theoritical cycle time, performance efficiency, net equipment effectiveness, overall equipment effectiveness dan total effective equipment productivity. Nilai OEE rata-rata pada kondisi awal dari bulan Juli sampai September 2007 adalah 69.55%. Implementasi TPM pada PT. Nusa Toyotetsu Corporation. dilakukan dengan maximizing Overall Equipment Effectiveness atau minimasi 'six big losses', autonomous maintenance dan planned maintenance. Kemudian dilakukan perhitungan kembali nilai efektifitas mesin dengan langkah perhitungan yang sama dan di peroleh nilai OEE rata - rata pada kondisi usulan penerapan dari bulan Oktober sampai Desember 2007 adalah 72.81%. Terdapat kenaikan persentase sebesar 3.26% dari kondisi sebelum penerapan dan setelah penerapan.

P PT. Nusa Toyotetsu Corporation is a company engaged in the automotive component industry. The products produced consist of various car components, and one of them is the parking brake lever assy 46210-0k040 or often called the innova handbrake. Some of the existing problems include the absence of a fixed machine maintenance schedule because so far the bare production machine will receive maintenance after damage occurs. In addition, the lack of operator knowledge about machine maintenance causes irregularities in the field, because they think it is the responsibility of the maintenance department. The most important problem is that machine damage often occurs, resulting in decreased machine effectiveness, thus harming the company. The initial stage is carried out by determining critical machines with a Pareto diagram that has a cumulative percentage of >80%, so that 5 critical machines are obtained, namely the SSW-1 machine, shearing machine, SSW-2 machine, adhesion machine and stamping machine (GANG 2) parking brake lever L / cable. The next step is to determine the critical components of each of these critical machines with a Pareto diagram that has a cumulative percentage of >80%, and 12 critical components are obtained. Continued by determining the distribution based on least square curve fitting to all critical components of the damage data and repair data. Then tested again with special tests for each selected distribution according to the largest off-fit index, then the parameter calculation, mean time to failure and mean time to repair, is carried out using the maximum likelihood estimator method, which aims to determine the preventive replacement time interval and inspection time interval. From the calculation of the preventive replacement time interval, the availability value can be obtained. With the implementation of preventive maintenance activities, there is an increase in reliability. The next stage is determining the effectiveness value of the machine by calculating the overall equipment effectiveness (OEE) with the calculation sequence of total available time, planned downtime, running time, equipment utilization, setup and adjustment, operating time, planned availability, unplanned downtime, net operating time, uptime, availability, total and good product, rate of quality, theoretical cycle time, performance efficiency, net equipment effectiveness, overall equipment effectiveness and total effective equipment productivity. The average OEE value in the initial condition from July to September 2007 was 69.55%. Implementation of TPM at PT. Nusa Toyotetsu Corporation. This was done by maximizing Overall Equipment Effectiveness or minimizing the 'six big losses', autonomous maintenance, and planned maintenance. Then, the machine effectiveness value was recalculated using the same calculation steps, and the average OEE value obtained under the proposed implementation conditions from October to December 2007 was 72.81%. There was a percentage increase of 3.26% from the conditions before and after implementation.

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