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All Journal Unistek: Jurnal Pendidikan dan Aplikasi Industri Science and Education Journal
Rakay Edhiargo Toyosito
Tangerang Raya University
Humanities Automotive Engineering Civil Engineering, Building, Construction & Architecture Computer Science & IT Education Electrical & Electronics Engineering Industrial & Manufacturing Engineering Social Sciences

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Penerapan Lean manufactturing Berbasis Value Stream Mapping (VSM), Failure Mode and Effect Analysis (FMEA) Untuk Mengurangi Downtime Cleaning dan Penggunaan Sodium Hydroxide di PT TES Baharui Gea; Sita Kurniaty Ratoko; Rakay Edhiargo Toyosito; Lifia Citra; Abimanyu Abimanyu
UNISTEK Vol. 13 No. 2 (2026): Agustus 2026 - Februari 2027
Publisher : UNIVERSITAS ISLAM SYEKH YUSUF TANGERANG

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33592/unistek.v13i2.8833

Abstract

The Cleaning In Place (CIP) process on Line 1 plays an important role in maintaining equipment cleanliness and ensuring product safety. However, excessive Cleaning Downtime increases production Downtime and Sodium Hydroxide (NaOH) consumption. This study aims to identify waste in the CIP process, determine the main causes of excessive Cleaning Downtime, and develop and implement improvement Actions to enhance Cleaning effectiveness. The methods used include Value Stream Mapping (VSM), Fishbone Diagram, Failure Mode and Effects Analysis (FMEA), and 5W1H. VSM results indicated that Cleaning Activities were classified as Non-Value-Added (NVA) Activities and significantly contributed to Downtime. FMEA identified the main causes of excessive Cleaning Downtime as the absence of nozzle valve covers (RPN=512), elevated machine positions that hinder inspections (RPN=448), insufficient awareness briefings (RPN=392), CIP frequency based on routine prActices (RPN=294), and the absence of NaOH usage records (RPN=252). Improvement Actions were developed using the 5W1H method and implemented through the installation of nozzle valve covers, CIP effectiveness verification, team awareness briefings, revision of the CIP matrix frequency, and NaOH usage monitoring. The implementation results showed that Cleaning frequency decreased from two times to one time per month, Cleaning Downtime decreased from 45.33 hours to 22.67 hours per month, and NaOH consumption decreased from 300 kg to 150 kg per month. These improvements successfully enhanced Cleaning effectiveness and chemical usage efficiency.
Optimalisasi Efektivitas Mesin Crusher Cello Dengan Overall Equipment Effectiveness (OEE) Dan Plan-Do-Check-Act (PDCA) Di Industri Makanan Ringan Rakay Edhiargo Toyosito; Vicky Fendy Hernawan; Angga Widyas Swara; Lifia Citra Ramadhanti
Science and Education Journal (SICEDU) Vol 5 No 3 (2026): Science and Education Journal 2026
Publisher : LPPM Universitas Pahlawan Tuanku Tambusai

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31004/sicedu.v5i3.1138

Abstract

This study aims to analyze and improve the effectiveness of the Cello Crusher machine in the production process at PT MYI by applying the Overall Equipment Effectiveness (OEE) and Plan-Do-Check-Act (PDCA) methods. The main problem identified was the high frequency of crusher blade replacement, which resulted in increased downtime and affected the stability of production output. This study used machine operational data from December 2025 to February 2026 as the pre-improvement data and data from March to May 2026 as the post-improvement data. Machine effectiveness was measured using the OEE method, which consists of Availability, Performance, and Quality. The root causes of the problems were identified using a Fishbone Diagram and Five Why Analysis, while the improvement process was implemented through the PDCA cycle. The results showed that the average OEE value before improvement was 79.74%, which was below the World Class OEE standard of 85%. The main factors contributing to the low machine effectiveness were the absence of a standard blade service life, the unavailability of a Standard Operating Procedure (SOP) for Preventive Maintenance, and the absence of a planned schedule for blade replacement and sharpening. Following the implementation of the improvement actions, the average OEE increased to 87.96%, representing an improvement of 8.22%. In addition, average downtime decreased from 106.25 minutes to 61.23 minutes per month, blade replacement frequency decreased from 7 to 4 times, and average production output increased from 4,717 kg to 5,380 kg. Therefore, the application of OEE and PDCA methods proved effective in improving machine effectiveness, reducing downtime, and supporting continuous improvement.
Co-Authors Abimanyu Abimanyu Angga Widyas Swara Baharui Gea Lifia Citra Lifia Citra Ramadhanti Sita Kurniaty Ratoko Vicky Fendy Hernawan