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All Journal Jurnal Ilmiah Teknik Mesin Jurnal Optimalisasi Jurnal Mekanova : Mekanikal, Inovasi dan Teknologi Jurnal Rekayasa Lingkungan Journal of Industrial and Engineering System
Muhazir, Achmad
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Aerospace Engineering Automotive Engineering Civil Engineering, Building, Construction & Architecture Control & Systems Engineering Decision Sciences, Operations Research & Management Engineering Environmental Science Industrial & Manufacturing Engineering Materials Science & Nanotechnology Mechanical Engineering Transportation

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Journal : jurnal optimalisasi

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Perencanaan Perawatan Mesin Building Dengan Metode Reliability Centered Maintenance (RCM) Muhazir, Achmad; Sinaga, Zulkani; Septiadi, Resky Dwi
Jurnal Optimalisasi Vol 10, No 1 (2024): April
Publisher : Universitas Teuku Umar

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.35308/jopt.v10i01.9263

Abstract

PT. Bridgestone Tire Indonesia is a tire manufacturing company. Machines that work continuously and lack of stock availability of machine spare parts cause damage and increase maintenance costs. To reduce the occurrence of damage and increase maintenance costs, it is necessary to have an optimal maintenance policy so that the machine can operate well. To overcome the problems in this research using the Reliability Centered Maintenance (RCM) method, the first step is determining the critical components on the machine, preparing the FMEA table based on the function data of the components and maintenance reports and calculating the Risk Priority Number (RPN), then calculating the MTTF and MTTR to determine maintenance and repair intervals and find optimal total maintenance costs. Machine building has the highest frequency of downtime so this research will focus on machine building components. The results of data processing show that the highest frequency of machine damage and total downtime is the cause of hose component failure due to poor hose quality and seal components becoming worn, causing increased frequency of damage, downtime and maintenance costs. Based on maintenance cost calculations using the RCM method, hose and seal components experienced a decrease in costs, namely hose components by 55.13% and seal components by 25.45%. The proposed building machine maintenance for hose and seal components in particular is to carry out scheduled tasks, scheduled exhaust tasks, and default actions with the task category of finding failures and results for maintenance time intervals for hose components of 280.81 hours and for seal components of 134.08 hours.
Perencanaan Analisis Pengendalian Kualitas Untuk Menurunkan Cacat Thickness Produk Kemasan Sauce Powder Pada Mesin Extruder Dengan Metode Failure Mode and Effect Analysis (FMEA) Sinaga, Zulkani; Muhazir, Achmad; Dewi, Deby Cika
Jurnal Optimalisasi Vol 11, No 1 (2025): April
Publisher : Universitas Teuku Umar

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.35308/jopt.v11i1.11709

Abstract

PT. XYZ Packaging Division is a company engaged in the food sector, especially the packaging sector. In 1 year of sauce powder packaging production, there were defective products produced exceeding the company's permitted limits, and the highest defect value was 4.7%. The highest percentage of defects occurred in the extruder process, this study will focus on the analysis of defective products produced from the extruder process. The high level of defective products in the sauce powder packaging production process occurs in the extruder process, namely thickness variation type defects. To reduce the level of defective products that occurred in this study, failure mode and effect analysis (FMEA) and seven tools were used, this method can analyze and reduce the level of product defects through a product failure model based on calculations of severity, occurrence and detection, then the RPN (risk Priority Number) value will be known, the cause of failure that has the highest RPN, that is the possible cause of high defects produced in the production process. From the results of the study, it is known that the dominant factor that causes the high level of defects in thickness variations is caused by dirty material factors and problematic machine factors in the polymer flow process. The results of problem solving with FMEA and seventools obtained a significant reduction in the level of defects in the extruder process from 3% to 1.4%, the recommended improvement results can reduce the level of defects in the extruder process to below the standard set by the company, which is 2.5%.
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.
Integrasi Six Sigma (DMAIC) dan Metode Taguchi untuk Optimasi Parameter Proses dan Reduksi Defect pada Produksi Aluminium Foil Sinaga, Zulkani; Muhazir, Achmad; Rukmayadi, Dede; Putra, Afgan Sandy
Jurnal Optimalisasi Vol 12, No 1 (2026): April
Publisher : Universitas Teuku Umar

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.35308/jopt.v12i1.15026

Abstract

The high defect rate in aluminium foil production can reduce production efficiency and product quality. This study aims to analyze the main causes of defects and determine optimal process parameters to improve aluminium foil production quality. The research applies the Six Sigma approach through the DMAIC (Define, Measure, Analyze, Improve, Control) framework combined with the Taguchi method for process parameter optimization. In the measurement stage, the process capability analysis shows a Defects per Million Opportunities (DPMO) value of 85,084 with a sigma level of 3.116, indicating that the process performance is still at a moderate capability level. Root cause analysis using fishbone diagrams and Failure Mode and Effect Analysis (FMEA) identifies temperature and machine speed as the dominant factors affecting defect occurrence. Furthermore, Taguchi experimental design using an L9 orthogonal array is applied to determine the optimal parameter combination. The results show that the optimal parameters are a temperature of 154 °C and a machine speed of 250.208 m/min. The implementation of these parameters reduces defect levels, where the DPMO decreases to approximately 55,304 and the sigma level increases to about 3.35, indicating an improvement in process capability and stability. This improvement is also supported by the control chart results, which show that the process is within statistical control limits after improvement. Therefore, the integration of Six Sigma and Taguchi methods is proven effective in reducing defects, improving process capability, and enhancing the overall quality of aluminium foil production.
Co-Authors Agung Siswahyu Alloysius Vendhi Prasmoro, Alloysius Vendhi Amalia, Risti Dewi, Deby Cika Fahri Santoso, Bima Faisal, Rohmat Helena Sitorus, Helena Illahi, Firman Muhammad Arifin Muzakkir Muzakkir Pratama, Gusti Andhika Aji Priana, Rafifah Bunga Putra, Afgan Sandy Rukmayadi, Dede Septiadi, Resky Dwi Sinaga, Zulkani Widyantoro, Murwan