Peningkatan produktifitas proses perakitan material ban motor dengan metode 8 step quality control circle di Divisi Assembly Building Tire
DOI:
https://doi.org/10.22441/oe.v11.3.2019.037Keywords:
produktivitas, 8 step QCC, building assembling ban motor, cycle timeAbstract
PT XYZ Tbk merupakan perusahaan yang bergerak di bidang manukatur ban dari semua tipe mulai dari ban traktor, truk, bus, mobil, hingga ban motor. Plant I merupakan salah satu bagian dari PT XYZ tbk yang khusus memproduksi ban motor tubeless. Pada tahun 2019, peningkatan permintaan ban motor tubeless meningkat dengan signifikan, khususnya pada ban ring 13 inch SS560 yang digunakan sebagai ban belakang motor Yamaha NMAX. Metode 8 step QCC memiliki alur yang tepat untuk membantu perusahaan melaksanakan improvement peningkatan produktivitas pada persoalan tadi. Pada step 1 dan 2 ditunjukkan data peningkatan permintaan sales sebesar 11% pada semester 2 2019, menjadikan target produksi permesin yang menjadi bottleneck yaitu building assembling, harus naik dari target 140 pcs/shift menjadi 155 pcs/shift. Penurunan cycle time menjadi langkah yang dipilih untuk meningkatkan output pencapaian dari mesin IMC 02.09 yang dipilih sebagai mesin model, dimana rata-rata pencapaiannya 136 pcs/shift, perlu naik 19 pcs/shift atau 13% untuk mencapai target perusahaan. Pada step 3 dan 4 dari hasil motion study dan analisa sebab akibat yang dilakukan, menunjukkan ada 2 tahapan kerja pada item nonvalue yaitu pengerolan manual pada sambungan ply 1 dan 2 bisa dihilangkan dengan simulasi penggantian bahan permukaan drum dari keras menjadi elastis dengan dilapisi karet. Selanjutnya pada item semivalue berdasarkan pareto tahapan kerja yang memiliki waktu terpanjang, diperolehlah 3 tahapan yang akan dilakukan improvement yaitu RS out, RS in, dan juga starroll manual kiri. Step 5 dan 6 menyusun pelaksanaan ke 4 rencana improvement tadi pada mesin IMC 02.09. Hasil improvement memberikan penurunan cycle time proses dari semula 123 detik/pcs menjadi 108 detik/pcs, atau meningkatkan pencapaian produksi dari 136 pcs/shift menjadi 154 pcs/shift, atau error sekitar 0,53% dari target. Peningkatan produktivitas mesin building assembling IMC 02.09 mampu memberikan potensi keuntungan bagi perusahaan sebesar Rp 3.615.840.000 per tahun.
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