Mengatasi Tingginya Waktu Downtime Tak Terencana pada Mesin Rotoman 630 di PT Yudhistira Ghalia Indonesia

Abstract

RIZQITA CHIARA MAHARANI. Mengatasi Tingginya Waktu Downtime Tak Terencana pada Mesin Rotoman 630 di PT Yudhistira Ghalia Indonesia. Dibimbing oleh PRAMONO D. FEWIDARTO. PT Yudhistira Ghalia Indonesia (PT YGI) merupakan salah satu perusahaan manufaktur yang bergerak dibidang percetakan buku pendidikan, PT YGI didirikan pada tahun 1971. Pelaksanaan magang industri dari bulan September 2024 hingga Januari 2025 di PT YGI dengan tujuan mengevaluasi masalah yang terjadi selama proses produksi percetakan. Selama melakukan aktivitas produksi, PT YGI mengalami permasalahan pada proses produksi, hasil identifikasi permasalahan melalui empat aspek utama yaitu, tata letak dan penanganan bahan, manajemen pengendalian kualitas, implementasi Total Productive Maintenance (TPM), dan implementasi lean manufacturing. Hasil analisis masalah signifikan ada pada aspek TPM dengan kerusakan komponen Fanbelt dan FCBH sebagai penyebab tingginya waktu downtime pada mesin Rotoman 630. Solusi yang diterapkan yaitu pembuatan jadwal periodic maintenance, membuat cleaning map dan defect map, dan pelaksanaan pelatihan breakdown kepada teknisi dan operator dengan materi berbasis aplikasi TPM untuk meningkatkan nilai Mean Time Between Failure (MTBF), dan menurunkan nilai Mean Time To Repair (MTTR), serta meningkatkan nilai availability, performance, dan quality yield.

RIZQITA CHIARA MAHARANI.Overcoming High Unplanned Downtime On Rotoman 630 Machine at PT Yudhistira Ghalia Indonesia. Supervised by PRAMONO D. FEWIDARTO PT Yudhistira Ghalia Indonesia (PT YGI) is a manufacturing company engaged in educational book printing, established in 1971. This final project was carried out during internship from September 2024 to January 2025 at PT YGI with the aim of evaluating and solving production process issues in the printing division. During production activities, PT YGI experienced issues that led to a decrease in effective production time. Problem identification focused on four key aspects: layout and material handling, quality control, Total Productive Maintenance (TPM), and lean manufacturing. The most urgent issue was in the TPM aspect, where repeated failures of the Fanbelt and FCBH components caused high unplanned downtime on the Rotoman 630 machines, which are the main printing units producing. Implemented solutions included is scheduling periodic maintenance, creating cleaning and defect maps, and delivering TPM-based breakdown training to technicians and operator for increasing Mean Time Between Failure (MTBF), reducing Mean Time To Repair (MTTR), and improving availability, performance, and quality yield.