Perencanaan Pengurangan jumlah Broken Bag Pada Semen Kantong Dengan Metode DMAIC Di PT Solusi Bangun Indonesia Narogong Plant
Abstract
PT Solusi Bangun Indonesia merupakan sebuah perusahaan terbesar dalam industri semen di Indonesia dengan total kapasitas produksi mencapai 14,86 juta ton semen per tahun. Pada proses produksi di PT Solusi Bangun Indonesia Narogong Plant terdapat dua area yaitu NAR 1 dan NAR 2, keduannya mempunyai area packhouse yang berfungsi sebagai tempat untuk megemas semen sebelum akhirnya di jual kepada konsumen. Area pack house NAR 2 merupakan area pengemasan semen untuk jenis semen kantong. Metode Penyelesaian solusi yang akan digunakan dalam penyelesaian Mengurangi tingkat broken bag adalah menggunakan metode DMAIC (define, measure, analyze. improve, dan control), Failure mode and effect analysis, dan Value Stream Mapping. Penelitian dilakukan untuk mengurangi tingkat kejadian Broken Bag diawali dengan menganalisa faktor penyebab terjadinya broken bag. Setelah itu, identifikasi frekuensi terjadinya faktor tersebut sehingga dapat diketahui frekuensi terbanyak yang menyebabkan permasalahan tersebut. Berdasarkan analisa yang telah dilakukan menggunakan metode FMEA (Failure Mode and Effect Analysis) dihasilkan fator penyebab terjadinya broken bag di area belt conveyor adalah formasi bag error, bag malang saat melintas di belt conveyor dan safety guard yang tajam. Namun, cause of failure Formasi Bag Error memiliki rating nilai Risk Priority Number paling tinggi yaitu sebesar 504 dengan persentase sebesar 43,1%. Adapun saran yang dapat dilakukan diantaranya memasang alat pengingat berbasis sensor yang dipasang mesin packer , Membuat
alat monitoring yang terdapat di control room yang sudah sinkron dengan mesin packer maupun palletizer, Membuat pelatihan khusus untuk seluruh operator terkait penggunaan mesin packer dan palletizer PT Solusi Bangun Indonesia is the largest company in the cement industry in Indonesia with a total production capacity of 14.86 million tons of cement per year. In the production process at PT Solusi Bangun Indonesia Narogong Plant there are two areas, namely NAR 1 and NAR 2, both of which have a packhouse area that functions as a place to grind cement before finally being sold to consumers. In the production process at PT Solusi Bangun Indonesia Narogong Plant there are two areas, namely NAR 1 and NAR 2, both of which have a packhouse area that functions as a place to grind cement before finally being sold to consumers. The NAR 2 pack house area is a cement bagging area for the type of bag cement. The solution solution that will be used in solving Reducing broken bag rates is using DMAIC methods (define, measure, analyze. improve, and control), Failure mode and effect analysis, and Value Stream Mapping. Research was conducted to reduce
the incidence rate of broken bags starting with analyzing the factors that cause broken bags. After that, identify the frequency of occurrence of these factors so that the most frequency that causes the problem can be known. Based on the analysis that has been carried out using the FMEA (Failure Mode and Effect Analysis) method, the cause of broken bags in the belt conveyor area is the formation of bag errors, poor bags when passing on the belt conveyor and sharp safety guards. However, the cause of failure of the Bag Error Formation has the highest Risk Priority Number value rating of 504 with a percentage of 43.1%. The suggestions that can be done include installing sensor-based reminder devices installed by packer machines, Making monitoring tools in the control room that are synchronized with packer machines and palletizers, Making special training for all operators related to the use of packer machines and palletizers.