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All Journal Sinergi Jurnal Ilmiah Teknik Mesin JIEMS (Journal of Industrial Engineering and Management Systems) JSI (Jurnal sistem Informasi) Universitas Suryadarma JURNAL KAJIAN TEKNIK MESIN Jurnal Optimalisasi Jurnal Mekanova : Mekanikal, Inovasi dan Teknologi Jurnal Ilmiah Vastuwidya Journal of Industrial and Engineering System Jurnal ABDIMAS (Pengabdian kepada Masyarakat) UBJ Jurnal Polimesin Metalik: Jurnal Manufaktur, Energi, Material Teknik
Sinaga, Zulkani
Program Studi Teknik Industri, Fakultas Teknik, Universitas Bhayangkara Jakarta Raya
Aerospace Engineering Humanities Automotive Engineering Civil Engineering, Building, Construction & Architecture Computer Science & IT Control & Systems Engineering Decision Sciences, Operations Research & Management Electrical & Electronics Engineering Energy Engineering Environmental Science Industrial & Manufacturing Engineering Law, Crime, Criminology & Criminal Justice Materials Science & Nanotechnology Mechanical Engineering Social Sciences Transportation

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Upaya Meningkatkan Produksi Pada Line Machining Crankcase K-58 Dengan Menggunakan Total Productive Maintenance (TPM) dan Failure Mode and Efect Analysis (FMEA) Muhazir, Achmad; Sinaga, Zulkani; Illahi, Firman
Jurnal Optimalisasi Vol 10, No 2 (2024): Oktober
Publisher : Universitas Teuku Umar

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.35308/jopt.v10i2.10552

Abstract

This study aims to improve production achievement and minimize failures and losses that occur in the Machining Crankcase K-58 line at PT XYZ. The production target was not achieved due to the high frequency of setups on the Fine Boring machine, broken cutting tools, and the large number of product rejects during the production process. The analysis is carried out using the Total Productive Maintenance (TPM) method, namely by calculating the machine's KPI via OEE then identifying it based on the six big losses, so that the root cause of the damage can be identified, while Failure Mode and Effects Analysis (FMEA) is to identify losses based on the mode of damage that occurs. from the known value of the Risk Priority Number (RPN) of critical components that cause machine failure. Based on the calculation of Overall Equipment Effectiveness (OEE) for the year 2023, an OEE value of 76.2% was obtained. The highest value of the Six Big Losses was in the Reduced Speed Losses category, with a percentage of 14.21%. After improvements with the 8-pillar TPM approach, particularly through autonomous maintenance, the OEE value increased by 9.3% to 85.5% in April 2023. The Availability Rate reached 96.3%, the Performance Rate was 91.2%, and the Quality Rate was 97.4%. The improvements included the implementation of autonomous maintenance, kaizen, and planned maintenance, which successfully enhanced the efficiency and effectiveness of production in the Machining Crankcase K-58 line.
MONITORING DAN PENGENDALIAN KELEMBABAN, SUHU PADA TANAMAN MENGGUNAKAN METODE SISTEM IRIGASI PANCAR Warta, Joni; Noe’man, Achmad; Sinaga, Zulkani
JSI (Jurnal sistem Informasi) Universitas Suryadarma Vol 8 No 2 (2021): JSI (Jurnal sistem Informasi) Universitas Suryadarma
Publisher : Universitas Dirgantara Marsekal Suryadarma

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.35968/jsi.v8i2.714

Abstract

AbstractThe growth of plants requires watering the plants so monitoring is necessary. Monitoring is carried out for the process of watering plants running optimally according to plant needs based on soil moisture and room temperature. Soil moisture explains that it settles between the soil pores, this is also due to evaporation of the soil surface, transpiration and infiltration. The purpose of this research is to do watering using a jet irrigation system so that it is done automatically in watering the soil according to the humidity and temperature required for the plants. The important factor of soil moisture is influenced by factors including the quality of the soil used as agricultural land, namely the life of the biological elements contained in the soil including hosts, pathogens, and also various other microorganisms, greatly affecting soil moisture. Determine the amount of water flow that flows from the water source to the soil element in order to get the appropriate level of humidity. In this study, the authors used cayenne pepper and red chili as the object of research, where these plants can grow at an optimal temperature of 24˚C – 28˚C, so it is necessary to monitor temperature and soil humidity using Arduino sensors to create a jet irrigation system. Keywords : Monitoring; Arduino Sensors; Water discharge; Radiant irrigation system
Enhancing production effectiveness of the K-58 crankcase machining line through integrated TPM–FMEA approach Sinaga, Zulkani; Sinaga, Jhonni
Jurnal Polimesin Vol 23, No 6 (2025): December
Publisher : Politeknik Negeri Lhokseumawe

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30811/jpl.v23i6.8231

Abstract

On the Crankcase K-58 machining line, several performance gaps were identified, including inconsistent cycle time, frequent unplanned downtime, and tool-change irregularities that caused the output to fall below the company targets. This study aims to enhance the production effectiveness of the K-58 crankcase machining line by applying an integrated Total Productive Maintenance (TPM) and Failure Mode and Effects Analysis (FMEA) approach. The initial performance evaluation, using Overall Equipment Effectiveness (OEE) in 2024, showed an average score of 76.2%, indicating significant losses in availability and performance rates. Quantitative analysis was conducted through OEE and Six Big Losses assessments, while FMEA was used to prioritize failure points based on Risk Priority Number (RPN). Improvement actions implemented included autonomous maintenance reinforcement, scheduled preventive maintenance, operator skill development, coolant-condition control, and quick-change adjustments. After implementation, OEE of the machining line increased to 85.5%, meeting the its target. Reduced speed losses improved by more than 45%, while setup and adjustment losses decreased by over 50%. These results confirm that the integrated TPM–FMEA approach is effective for enhancing machining-line performance and reliability.
A predictive safety and maintenance framework for railway locomotives: integrating HAZOP, FMEA, and IoT-based risk mitigation Muhendra, Rifki; Fadhlurrohman, Zain; Adi, Farhan Indra Pratama; Sinaga, Zulkani; Turseno, Andi
SINERGI Vol 30, No 1 (2026)
Publisher : Universitas Mercu Buana

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.22441/sinergi.2026.1.014

Abstract

Safety and maintenance efficiency are critical challenges in the railway industry, particularly in the use of lifting jacks for locomotive maintenance. This study proposes a predictive maintenance framework that integrates the Hazard and Operability Study (HAZOP), Failure Mode and Effects Analysis (FMEA), and Internet of Things (IoT) technology to detect potential failures in real time. A case study was conducted at a locomotive maintenance depot in Indonesia, where several occupational accidents had been recorded due to lifting jack malfunctions. Based on HAZOP and FMEA analyses components such as stoppers and drive motors were identified as having high Risk Priority Numbers (RPN), each reaching 512, indicating significant failure risks. The proposed IoT system employs HCSR-04 and MPU6050 sensors to accurately monitor the height and inclination of the equipment. Evaluation results show that the system effectively detects anomalies with minimal data deviation and a low data loss rate during a 10-day testing period. The implementation of this system significantly reduces workplace accident risks, improves maintenance efficiency, and supports digital transformation within the industrial environment. These findings demonstrate that the integration of HAZOP, FMEA, and IoT is effective for risk mitigation and can be replicated in other railway components. Moreover, this research opens new avenues for developing AI-based predictive systems and implementing digital twins as part of future smart maintenance strategies.
Peningkatan Kesadaran Pengelolaan Sampah Berbasis 3R Dan Pemberdayaan Masyarakat Melalui Program KKN Di Desa Srimukti, Tambun Utara Sinaga, Zulkani; Aryan, Fajar Dwi; Fauzan, Gufron; Ismail, Muhamad Ikhtiar Raihan; Nugraha, Naufal; Aveline, Malita; Saputra, Dias Cahya; Mefia, Dinda; Putra, Hanifsa; Pradana, Satria Wahyu
Jurnal Pengabdian kepada Masyarakat UBJ Vol. 8 No. 2 (2025): Juni 2025
Publisher : Lembaga Penelitian Pengabdian kepada Masyarakat dan Publikasi Universitas Bhayangkara Jakarta Raya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31599/pgvy5k77

Abstract

KKN Group 9 from Bhayangkara University Jakarta Raya carried out its program in Srimukti Village, Tambun Utara Subdistrict, Bekasi Regency, an area with development potential but challenged by poor environmental hygiene and a lack of public facilities. The work programs included education on waste management using the 3R (Reduce, Reuse, Recycle) concept, distribution of trash bins, community clean-up activities, installation of street name signs, a coloring competition for children, and the construction of a low-smoke waste incinerator. An educational and participatory approach was employed to increase community awareness and involvement. The results showed improved public awareness regarding environmental cleanliness, better area organization through signage, and enhanced children's creativity through competitions. Students also gained valuable experience in community interaction, leadership, and implementing local solutions. This program was considered effective in promoting a cleaner, more organized, and empowered village through collaboration between students and residents.
Co-Authors Achmad Muhajir Achmad Muhazir Adi, Farhan Indra Pratama Ahmad Nurwibowo Amalia, Risti Ardi Arya Yusanto Aryan, Fajar Dwi Aveline, Malita Dewi, Deby Cika Fadhlurrohman, Zain Fauzan, Gufron Hael G, M. Habib Hartono, Rudi Helena Sitorus, Helena Hermawan, Ridwan Catur Illahi, Firman Ismail, Muhamad Ikhtiar Raihan Joniwarta Kawi, Ronny Octoriza Mefia, Dinda Mochamad Ardan Muhamad Ilham Fuadi Muhammad Arifin Muhazi, Achmad Muhazir, Achmad Muhendra, Rifki Muzakkir Muzakkir Noe’man, Achmad Nugraha, Naufal Pradana, Satria Wahyu Pratama, Gusti Andhika Aji Priana, Rafifah Bunga Putra, Hanifsa Rudi Hartono Saputra, Dias Cahya Sarifuddin Sarifuddin Septiadi, Resky Dwi Sinaga, Jhonni Solihin Solihin Solihin Solihin Syaiful Islam Tri Maryanto Turseno, Andi Widyantoro, Murwan Zaenal Abidin