Analisis Efektivitas Mesin Rewinder dengan Metode Overall Equipment Effectiveness (OEE) dan Six Big Losses pada Area Finishing di PT. XYZ

Abstract

PT. XYZ is a manufacturing company that produces paper. The types of paper produced are highly varied, one of which is roll paper manufactured by the rewinder machine. Based on data from the rewinder machine in the finishing area for the period of January to September 2024, the machine experienced significantly high unplanned downtime compared to planned downtime. This condition led to the production targets not being met due to suboptimal machine performance. The objective of this research is to analyze the effectiveness of the rewinder machine, identify the highest contributing losses on the machine with the lowest effectiveness, and propose improvement suggestions. One method used to measure machine effectiveness is the Overall Equipment Effectiveness (OEE) method. OEE is a metric used to assess how effectively a manufacturing operation is utilized. Additionally, the FMEA method is used to identify and prioritize potential failures and corrective actions. Based on the research results and monitoring dashboard, it was found that rewinder machine 02 had the lowest Overall Equipment Effectiveness (OEE) score of 36.82%. Based on the Pareto diagram, the percentage of losses that affect the effectiveness value of the rewinder 02 machine is reduced speed losses of 41.05% and setup and adjustment loss of 31.14%. Furthermore, an analysis was carried out using FMEA based on the root cause of the fishbone diagram. Based on the RPN value in the FMEA analysis, it can be seen that the main cause of reduced speed loss is poor roll quality with an RPN value of 360 and the main cause of setup and adjustment loss is untrained operators with an RPN value of 320. The proposed improvements that can be made to reduce the value of reduced speed loss are to conduct inspections of incoming raw materials and quality control at each stage of production. This aims to ensure that the quality of raw materials is in optimal condition so that it can reduce the risk of torn paper during the production process. In addition, the proposed improvements that can be made to reduce the value of setup and adjustment loss are to carry out routine training for operators on the procedure for adjusting machine settings. This training aims to improve operator skills in adjusting machines more quickly and accurately, so that it can reduce setup time and increase the efficiency of the overall production process.