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Indra Rizki Pratama
Politeknik STMI Jakarta
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Sosialisasi Metode 5R untuk Perbaikan Sistem Kerja Pada Bengkel Sepeda Motor di Jakarta Utara Pratama, Indra Rizki; Aisyah, Siti; Imansuri, Febriza; Sumasto, Fredy
Jurnal Pengabdian Masyarakat Bangsa Vol. 2 No. 4 (2024): Juni
Publisher : Amirul Bangun Bangsa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.59837/jpmba.v2i4.945

Abstract

Pekerjaan dalam industri otomotif memiliki resiko Keselamatan dan Kesehatan Kerja (K3) bagi para pekerja dan orang lain yang sedang berada di lingkungan tersebut. Bahaya dapat diminimalisir dengan perbaikan kerja. Salah satu metode untuk perbaikan kerja adalah metode 5R. Metode 5R adalah kepanjangan dari Ringkas, Rapi, Resik, Rawat dan Rajin. Metode  5R merupakan sebuah pendekatan untuk mengatur lingkungan kerja dengan cara mengeliminasi waste sehingga tercipta lingkungan kerja yang efektif, efisien dan produktif. Bengkel Bina Motor berlokasi di Jalan Sungai Bambu, Kecamatan Tanjung Priok, Kota Jakarta Utara. Berdasarkan hasil observasi awal pada bengkel bina motor, tim PkM menemukan bahwa bengkel belum menerapkan 5R. Hal tersebut ditunjukkan dengan kondisi lingkungan bengkel dan peralatan yang tidak rapi. Pengabdian kepada masyarakat bersifat sosialisasi mengenai metode 5R, pengetahuan dasar konsep 5R, serta tahapan-tahapan untuk mengimplementasikan metode 5R di bengkel sepeda motor sebagai bentuk pengembangan, penyebarluasan ilmu pengetahuan, teknologi dan wawasan dengan melibatkan 2 orang montir bengkel Bina Motor. Pelaksanaan pengabdian ini dimulai dengan observasi kondisi awal bengkel, dilanjutkan dengan sosialisasi & edukasi metode 5R serta pendampingan implementasi metode 5R di lapangan. Hasil dari kegiatan pengabdian ini adalah metode 5R telah di implementasikan di bengkel Bina Motor untuk mengurangi bahaya ditempat kerja bagi para montir.
Application of Single Minute Exchange Die (SMED) Method to Minimize Setup Time on 350T Capacity Molding Machine Sumasto, Fredy; Arrofah, Muhammad Arif; Pratama, Indra Rizki; Purbaningrum, Sanurya Putri; Satria, Adam; Rapi, Amrin
Jurnal Inotera Vol. 10 No. 1 (2025): January-June 2025
Publisher : LPPM Politeknik Aceh Selatan

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31572/inotera.Vol10.Iss1.2025.ID422

Abstract

This study aims to apply the Single Minute Exchange of Die (SMED) method in reducing setup time on a 350T capacity molding machine at PT HMG. The data collection results showed that the frequency of mold changes reached 70 times a month, with the average time required for mold changes before the implementation of SMED 173 minutes. After the implementation of SMED, the mold change time was successfully reduced to 64 minutes, reflecting a decrease of 63%. The implementation of SMED was carried out through several stages, including converting internal activities to external ones, which aimed to reduce machine downtime. Optimization of the remaining activities was also carried out, such as reducing the temperature drop time on the barrel and hot runner, which previously took 15 minutes, now only 5 minutes. The final results showed that machine downtime cost savings reached Rp11,200,000 per month after the implementation of SMED, with total downtime costs decreasing from Rp30,274,999 to Rp19,074,999 per month. This study proves that implementing the SMED method can significantly improve time efficiency, reduce production costs, and create more efficient operational standards. The findings provide a solid basis for further development in industry manufacturing practices.
PERANCANGAN PALLET DELIVERY UNTUK MEMINIMASI RISIKO KELUHAN AKIBAT KERJA MENGGUNAKAN METODE RAPID ENTIRE BODY ASSESSMENT (REBA) DI PT. XYZ Imdam, Irma Agustiningsih; Kurnianto, Radif; Sukmawati, Wilda; Sumasto, Fredy; Pratama, Indra Rizki; Marizka, Dewi Auditiya
Jurnal Ilmiah Teknik Industri Vol. 12 No. 3 (2024): Jurnal Ilmiah Teknik Industri : Jurnal Keilmuan Teknik dan Manajemen Industri
Publisher : Program Studi Teknik Industri, Fakultas Teknik Universitas Tarumanagara

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24912/jitiuntar.v12i3.32781

Abstract

Pallet Delivery Design at PT. XYZ is intended to overcome operator working posture problems in the manual process of tying boxes with ropes, so as to reduce complaints of Musculoskeletal Disorders (MSDs) in operators. Analysis of MSDs complaints was carried out by distributing the Nordic Body Map (NBM) questionnaire to three workers with the results that they experienced complaints of calf, back and knee pain. Based on the results of the Nordic Body Map questionnaire, a Rapid Entire Body Assessment (REBA) analysis was carried out, namely to assess the level of risk. In the initial assessment, REBA produced a score of 9 which indicates a high risk with the use of the tool used. To find out the specifications of the tool to be designed, it is done by measuring the operator's anthropometric data, followed by product design using the Need, Idea, Decision, and Action (NIDA) method as a design approach and the next stage is simulated in CATIA software to confirm risk reduction. The design simulation shows a decrease in the REBA value from 9 to 2, thereby reducing the risk of MSDs for workers.
Strategic Line Balancing for Enhanced Efficiency in Solar Module Manufacturing: A Comprehensive Study in the Renewable Energy Sector Imansuri, Febriza; Sumasto, Fredy; Pratama, Indra Rizki; Aminuddin, Muhammad; Saputra, Alfiolani
IJIEM - Indonesian Journal of Industrial Engineering and Management Vol 5, No 3: October 2024
Publisher : Program Pascasarjana Magister Teknik Industri Universitas Mercu Buana

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.22441/ijiem.v5i3.22972

Abstract

This study endeavors to enhance the productivity of solar module production in a renewable energy conversion company. The existing production line needs help in achieving the daily target of 64 units, resulting in an actual output of only 40 units. This study focuses on optimizing the production line by considering processing time adjustments and operator flexibility. To accurately measure working time, we incorporate operator flexibility and adjustment factors in the planning phase of solar module production. The primary objective is establishing an optimal production trajectory by balancing the load and capacity across workstations, thereby elevating overall production efficiency. The approach involves the application of the trial-error method and the shortest operation time method, implemented through POM QM software. Through meticulous data analysis, we determine that the trial-error process yields the most optimal results. Post-implementation, improvements are evident as the solar module production capacity increases to 60 units per day from the initial 40 units. Additionally, the idle time ratio on the assembly line to available time diminishes to 13.17% after optimization. This study contributes valuable insights into the effective enhancement of solar module production lines, emphasizing practical methodologies and software-assisted techniques for achieving substantial productivity gains in the renewable energy sector. 
Analysis of Work Posture and Improvement of Worker Activities at a Four-Wheeled Vehicle Lighting Company Imansuri, Febriza; Ardiansyah, Muhammad; Irhannudin, Muhammad; Rahimun, Farhan Bagus; Priandi, Fajar Putra; Pratama, Indra Rizki; Wulansari, Isma
IJIEM - Indonesian Journal of Industrial Engineering and Management Vol 6, No 1: February 2025
Publisher : Program Pascasarjana Magister Teknik Industri Universitas Mercu Buana

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.22441/ijiem.v6i1.25345

Abstract

PMG, Ltd is a company that manufactures and subcontracts for car lighting companies.The problem on the automobile lamp factory floor is that workers do repetitive operations and lifting loads manually without using tools. The goal of this research is to determine the risk level of work posture and provide recommendations for improvements to four-wheeled vehicle lighting component companies. The methods used to assess operator working posture are the Nordic Body Map (NBM), Quick Exposure Check (QEC) and Ovako Working Posture Analysis System (OWAS) questionnaires. Based on the results of the NBM questionnaire, Musculoskeletal Disorder (MSD) symptoms were found on the neck, back, hands and feet. The score for the QEC method is 65.43%, which means further research and changes are needed, and the OWAS method is in category 2, which means that corrective action is needed in the near future. Improvements in working posture were carried out by redesigning the work table according to anthropometric ergonomics principles and reducing the flow of stages in the lamp production process from 11 steps to 8 work steps. 
Strengthening screw shaft measurement system in teaching factory through measurement system analysis: A case study Sumasto, Fredy; Samudra, Bayu; Hakim, Ali Rachman; Imansuri, Febriza; Pratama, Indra Rizki
Journal Industrial Servicess Vol 11, No 1 (2025): April 2025
Publisher : Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.62870/jiss.v11i1.30298

Abstract

Ensuring accurate measurement of precision components is critical in the automotive industry. This study investigates measurement challenges for screw shaft components at the Teaching Factory of Politeknik STMI Jakarta. The initial measurement system performed poorly, with 100% total variation attributed to measurement error and a Number of Distinct Categories (Ndc) of 1, indicating an inability to distinguish product variations. To address this, a Measurement System Analysis (MSA) using the Gage Repeatability and Reproducibility (GRR) method was conducted. Improvements, including operator training, regular calibration, and a custom jig fixture, were implemented. As a result, the GRR value decreased to 26.27%, with repeatability contributing 25.40% and reproducibility 6.74%. The Ndc value increased to 5, reflecting improved capability to differentiate product variations. These outcomes demonstrate that MSA is an effective strategy for evaluating and enhancing measurement systems. It is particularly valuable in vocational education settings to ensure measurement reliability, maintain quality standards, and support industry-relevant skill development.
Implementation of Min-Max Stock Insert Components to Prevent Lost Opportunity Tooling Case Study: Automotive Component Company Imansuri, Febriza; Hermawan, Yuda; Sumasto, Fredy; Pratama, Indra Rizki; Dendra, Feby Gusti; Imdam, Irma Agustiningsih
IJIEM - Indonesian Journal of Industrial Engineering and Management Vol 6, No 2: June 2025
Publisher : Program Pascasarjana Magister Teknik Industri Universitas Mercu Buana

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.22441/ijiem.v6i2.26678

Abstract

Inadequate or delayed supply of raw materials or components needed for production can lead to line stoppages. Reducing the frequency and duration of line stoppages is crucial for maintaining efficiency and meeting production targets. It can happen due to logistics problemsThis research was conducted in the logistics department of an automotive component company. One of the causes is the procurement of tooling, which needs to be improved for production needs. The tooling factor is part of the logistics scope and is the highest factor causing lost opportunities and line stoppages. To minimize the impact of line production stoppages, manufacturers often implement strategies like implementing a minimum stock of insert components. The problem-solving methodology includes a five whys analysis, conducting a Pareto diagram, determining the service level of the stock level, and calculating the maximum-minimum stock level. Based on the result, 17 types of inserts must apply stock levels to avoid stock shortages.
Co-Authors Abdul Wahid Arohman Abdussalam Topandi Ahlan Ismono Ali Rachman Hakim Amrin Rapi Anita Putri Permatasari Ardy Riyanto Arif Dzulfikar Arrofah, Muhammad Arif B. Handoko Purwojatmiko Bayu Samudra Bismo Zulfikar Mustofa Busharmaidi Desy Agustin Dewi Auditiya Marizka Dianasanti Salati Emi Rusmiati Fauziah Aulia Febriza Imansuri Febriza Imansuri Febriza Imansuri Feby Gusti Dendra Hakim, Ali Rachman Hermawan, Yuda Ibnu Syihab Imansuri, Febriza Imansuri, Febriza Irhannudin, Muhammad Irma Agustiningsih Imdam Isma Wulansari Isma Wulansari Isma Wulansari Khadijah Sayyidatun Nisa Kingwan Kingwan Kurnianto, Radif Lucyana Tresia Muhamad Fahrul Rozi Muhammad Aminuddin, Muhammad Muhammad Ardiansyah Muhammad Raihan Akbar Priandi, Fajar Putra Rafi Ramadhani Jiwanto Rahimun, Farhan Bagus Rahmat Dwi Febriyanto Rahmat Dwi Febriyanto Samudra, Bayu Sanurya Putri Purbaningrum Saputra, Alfiolani Satria, Adam Septian Adi Cahyo Shabrina Razan Putri Pribadi Shafiratul Fajri Harisul Husna Siti Aisyah Siti Aisyah Sumasto, Fredy Wilda Sukmawati Wulansari, Isma