ANALISIS KINERJA MESIN FLEXO 15 INLINE DENGAN OEE DAN SIX BIG LOSSES DI PT XYZ

Abstract

Tingginya tingkat downtime pada mesin produksi dapat menurunkan produktifitas kerja dan menghambat pencapaian target produksi. PT XYZ menghadapi permasalahan pada mesin Flexo 15 Inline yang mengalami downtime tertinggi dibandingkan mesin flexo inline lainnya. Penelitian ini bertujuan untuk mengukur kinerja mesin Flexo 15 Inline menggunakan metode Overall Equipment Effectiveness (OEE), mengidentifikasi faktor dominan six big losses, serta memberikan alternatif rekomendasi perbaikan. Metode yang digunakan dalam penelitian ini mencakup perhitungan OEE, analisis six big losses, serta identifikasi akar penyebab menggunakan metode fault tree analysis (FTA). Hasil analisis menunjukkan bahwa rata-rata nilai OEE mesin Flexo 15 inline adalah 62%, nilai tersebut masih di bawah standar JIPM yaitu 85%. Kerugian terbesar berasal dari idle and minor stoppage dengan nilai 22%. Faktor utama penyebab downtime tersebut diidentifikasi melalui analisis diagram pareto dan FTA, didapatkan lima faktor dominan yaitu lap dies, sheet macet, dies miring, push bar bermasalah, dan penambalan dies. Rekomendasi perbaikan meliputi perancangan One Point Lesson (OPL), checksheet inspeksi dies, dan pelatihan operator.

High levels of downtime in production machines can reduce work productivity and hinder the achievement of production targets. PT XYZ faces issues with the Flexo 15 Inline machine, which records the highest downtime compared to other Flexo Inline machines. This study aims to evaluate the performance of the Flexo 15 Inline machine using the Overall Equipment Effectiveness (OEE) method, identify the dominant factors of the six big losses, and provide alternative improvement recommendations. The methods used in this study include OEE calculation, six big losses analysis, and root cause identification using Fault Tree Analysis (FTA). The analysis results show that the average OEE value of the Flexo 15 Inline machine is 62%, which is still below the JIPM standard of 85%. The highest loss comes from idle and minor stoppages, with a percentage of 22%. The main causes of this downtime were identified using Pareto diagram and FTA, revealing five dominant factors: dies cleaning, sheet jam, misaligned dies, trouble push bar, and dies backing. Improvement recommendations include the development of One Point Lessons (OPL), dies inspection checksheets, and operator training.