Analisis Reliability dan Overall Equipment Effectiveness Mesin Crusher Limestone di PT XYZ

Abstract

Unit crusher limestone merupakan tahap awal dalam proses produksi semen yang berperan penting dalam menjaga kontinuitas aliran material. Namun, tingginya downtime pada sistem Belt conveyor menyebabkan terganggunya proses operasional dan menurunkan kinerja unit crusher. Penelitian ini bertujuan untuk menganalisis tingkat reliability dan Overall Equipment Effectiveness (OEE) serta mengevaluasi efektivitas implementasi scrapper menggunakan pendekatan Focused improvement. Analisis dilakukan menggunakan diagram Pareto, Fishbone diagram, dan Nominal Group Technique (NGT) untuk menentukan penyebab dominan downtime. Hasil analisis menunjukkan bahwa Belt conveyor menjadi komponen dengan downtime tertinggi sebesar 90,28 jam dan penyebab utama gangguan adalah tidak adanya sistem self-cleaning. Perbaikan dilakukan melalui implementasi scrapper pada Belt conveyor. Hasil evaluasi menunjukkan downtime menurun menjadi 19,65 jam, nilai Mean Time Between Failure (MTBF) meningkat dari 98,33 jam menjadi 429,28 jam, sedangkan nilai Mean Time to Repair (MTTR) dan Mean Down Time (MDT) menurun menjadi 5,47 jam dan 6,55 jam. Selain itu, nilai OEE meningkat dari 65% menjadi 75% setelah implementasi.

The crusher limestone unit is an initial stage in cement production and plays an important role in maintaining material flow continuity. However, high downtime in the belt conveyor system disrupts operational processes and reduces crusher performance. This study aims to analyze reliability and Overall Equipment Effectiveness (OEE) and evaluate the effectiveness of scrapper implementation using a Focused Improvement approach. The analysis was conducted using Pareto diagrams, fishbone diagrams, and Nominal Group Technique (NGT) to determine the dominant causes of downtime. The results showed that the belt conveyor had the highest downtime of 90,28 hours, with the absence of a self-cleaning system identified as the main cause. Improvement was carried out through scrapper implementation on the belt conveyor. The evaluation results showed that downtime decreased to 19,65 hours, (MTBF) increased from 98,33 hours to 429,28 hours, while Mean Time to Repair (MTTR) and Mean Down Time (MDT) decreased to 5,47 hours and 6,55 hours, respectively. In addition, OEE increased from 65% to 75% after implementation.