EVALUASI SETUP TIME PROSES CIP ASEPTIC TANK DENGAN METODE PDCA (PLAN-DO-CHECK-ACTION) PADA LINI PRODUKSI SUSU READY TO DRINK DI PT XYZ

Abstract

Efisiensi operasional industri susu sangat dipengaruhi oleh setup time, khususnya pada proses Cleaning In Place (CIP) Aseptic Tank. Penelitian ini bertujuan mengidentifikasi faktor penyebab ketidakefisienan durasi CIP yang mencakup lima tahapan meliputi pre rinse, caustic, intermediate rinse, acid, dan final rinse, serta memberikan rekomendasi perbaikan menggunakan pendekatan Plan-Do-Check-Action (PDCA). Analisis diagram Pareto menunjukkan CIP Aseptic Tank merupakan kontributor losses terbesar kedua terhadap total kendala setup time. Aseptic Tank 5 teridentifikasi sebagai unit dengan performa CIP paling rendah, dengan hanya 6 dari 59 proses yang memenuhi standar waktu. Analisis Pearson correlation menunjukkan bahwa Pressure Supply memiliki korelasi negatif yang kuat terhadap durasi pada fase Caustic (r = -0,866), Intermediate Rinse (r = -0,782), dan Acid (r = -0,808). Sebaliknya, Conductivity Return memiliki korelasi positif yang kuat terhadap durasi pada fase Pre Rinse (r = 0,817) dan Final Rinse (r = 0,997). Melalui Root Cause Analysis (RCA), keterlambatan durasi dipicu oleh tekanan yang kurang optimal, sistem otomasi Programmabel Logic Controller (PLC) berbasis fixed timer yang tidak adaptif, serta keterlambatan respons operator pada panel Human Machine Interface (HMI). Rekomendasi perbaikan meliputi penyesuaian target Overall Equipment Effectiveness (OEE) menjadi 74%, revisi standar durasi CIP menjadi 2 jam 40 menit, dan implementasi One Point Lesson (OPL) untuk panduan respons panel HMI bagi operator. Simulasi optimalisasi pressure aseptic tank menjadi 1,40 bar melalui pemasangan orifice diproyeksikan meningkatkan wall shear stress sebesar 12%, memangkas durasi setup 8,58 menit (efisiensi 10,72%), serta menghemat penggunaan deterjen hingga 1.628 liter per siklus CIP.

The operational efficiency of the milk industry is highly influenced by setup time, particularly in the Aseptic Tank Cleaning In Place (CIP) process. This study aimed to identify the causes of CIP duration inefficiency, which included five stages i.e. pre-rinse, caustic, intermediate rinse, acid, and final rinse, and to provide improvement recommendations using the Plan-Do-Check-Action (PDCA) approach. Pareto chart analysis showed that Aseptic Tank CIP was the second largest contributor to losses in total setup time constraints. Aseptic Tank 5 was identified as the unit with the lowest CIP performance, with only 6 out of 59 processes meeting the time standard. Pearson correlation analysis indicated that Pressure Supply had a strong negative correlation with the duration of the Caustic (r = -0.866), Intermediate Rinse (r = -0.782), and Acid (r = -0.808) phases. Conversely, Conductivity Return had a strong positive correlation with the duration of the Pre Rinse (r = 0.817) and Final Rinse (r = 0.997) phases. Through Root Cause Analysis (RCA), duration delays were triggered by suboptimal pressure, a non adaptive fixed timer based Programmable Logic Controller (PLC) automation system, and delayed operator responses on the Human Machine Interface (HMI) panel. Improvement recommendations included adjusting the Overall Equipment Effectiveness (OEE) target to 74%, revisi the standard CIP duration to 2 hours and 40 minutes, and implementing a One Point Lesson (OPL) as a guide for operator responses on the HMI panel. The optimization simulation of the aseptic tank pressure to 1.40 bar through the installation of an orifice was projected to increase wall shear stress by 12%, cut the setup duration by 8.58 minutes (10.72% efficiency), and save detergent usage by up to 1,628 liters per CIP cycle.