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Analisis Pengurangan Waste Proses Produksi pada PT SP Manufacturing Simaremare, Erna; Elsya Paskaria Loyda Tarigan
JURNAL SURYA TEKNIKA Vol. 11 No. 1 (2024): JURNAL SURYA TEKNIKA
Publisher : Fakultas Teknik UMRI

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37859/jst.v11i1.6605

PT SP Manufacturing is a manufacturing company that operates in the field of wire harness production. When making wire harnesses at PT SP Manufacturing, waste still occurs. Waste in the production process is one of the biggest problems this company wants to solve. A defective product is a product that does not meet wire harness production standards so it cannot meet customer demand, and requires more space before rework is carried out, which causes inventory waste (Unnecessary Inventory). Reduced productivity and higher production costs are the result of this waste. The aim of this research is to use value stream mapping to identify waste in the production process and apply lean manufacturing techniques to reduce it. The results obtained are based on identification and analysis of existing problems as well as alternatives and improvements based on the formulation and objectives in the research. The largest waste in the wire harness production process of PT.SP Manufacturing is waste with a weight score of 60.89%, unknown inventory waste with a weight score of 39, 12%. The causal factors are workers who lack concentration, apply excess solder paste to the wire terminals, workers who pursue targets without paying attention to quality, resulting in defective products that require rework. The recommendations given to the company according to the fishbone diagram are proposed improvements to the wire harness production process to reduce defects and unnecessary inventory which refers to people, machines, methods and materials.

ANALISIS PREVENTIVE MAINTENANCE MESIN INJECTION MOLDING DI PT YEAKIN PLASTIC INDUSTRY BATAM Arnold Sihombing; Elsya Paskaria Loyda Tarigan
Computer Science and Industrial Engineering Vol 11 No 2 (2024): Comasie Vol 11 No 2
Publisher : LPPM Universitas Putera Batam

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PT Yeakin Plastic Industry is a company engaged in manufacturing plastic goods. The problem that occurs in this study is the high downtime that occurs on the injection molding machine. So that the amount of production does not reach the target. The purpose of this study is to determine the interval of preventive maintenance injection molding to minimize machine downtime. The method used in this research is Reliability Centered Maintenance (RCM). From the results of the study, it was found that the results of the weibull distribution obtained the maintenance interval of the A200 injection molding machine with the longest downtime, where there were 11 breakdowns in 6 months, and maintenance actions were carried out at the maintenance interval for 100.55 hours. On the A201 injection molding machine there are 8 breakdowns in 6 months, and maintenance actions are carried out at maintenance intervals for 144.44 hours. On the A202 injection molding machine there were 8 breakdowns in 6 months, and maintenance actions were taken at the maintenance interval for 122.97 hours.

PERANCANGAN ULANG TATA LETAK GUDANG DISTRIBUTOR BAN PADA PT XTC Lumban Toruan, Lionel Richie; Elsya Paskaria Loyda Tarigan
Computer Science and Industrial Engineering Vol 11 No 3 (2024): Comasi Vol 11 No 3
Publisher : LPPM Universitas Putera Batam

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33884/comasiejournal.v11i3.9057

The rapid development of global industries and technology has complicated the layout of warehouse facilities in manufacturing. PT XTC, a major tire distributor in Indonesia, faces inefficiencies in its warehouse layout, causing cross movements, poor space utilization, and difficulties for forklift operators. This study aims to redesign the tire layout in PT XTC’s distribution warehouse using the class-based storage method, which groups materials based on popularity to enhance efficiency and productivity. The study employs direct observation, interviews, and literature reviews, collecting data on tire quantities, material inflows, and outflows from October 2023 to March 2024. Data analysis includes calculating the frequency of material movements, classifying materials into fast-moving, medium-moving, and slow-moving categories, and measuring penangan material distances and costs in both the initial and proposed layouts. Results show that the class-based storage method groups materials into class A (67.4%), class B (18.3%), and class C (8.3%). The initial layout shows a material movement distance of 3,514,000 meters and handling costs of Rp.509,530,000, while the redesigned layout reduces these figures to 1,045,800 meters and Rp.151,641,000, respectively. The redesign provides a more efficient space and lower handling costs.

PERBAIKAN PROSES SEWING JUMBO BAG PADA PT SUTAN MORA TEKNOLOGI Sitinjak, Chanro; Elsya Paskaria Loyda Tarigan
Computer Science and Industrial Engineering Vol 11 No 2 (2024): Comasie Vol 11 No 2
Publisher : LPPM Universitas Putera Batam

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33884/comasiejournal.v11i2.9085

PT Sutan Mora Teknologi is manufacturing company engaged in the industry of making jumbo bags. The problem in this study is the result of curly stitch defects, stitches too edge, stitches not according to the pattern, broken stitches, jumping stitches, so it is not strong to withstand the load on the jumbo bag. The purpose of this study is to determine the cause of the defects of curly stitches, stitches too edge, stitches not according to the pattern, broken stitches, jumping stitches, so that it cannot withstand the load on the jumbo bag and to improve the sewing process of the jumbo bag. The method used in this research is the Six Sigma method with the DMAIC approach. From the results of this study, it is found that the cause of defects in curly stitches is that the lifeboat is often damaged, with an RPN value of 336, the seam is too edge is the seam position does not fit with an RPN value of 245, the seam does not fit the pattern is the seam pattern does not fit with an RPN value of 210, the seam breaks is the operator lacks knowledge with an RPN value of 256, the seam jumps is the work method is difficult to apply with an RPN value of 336. Improvements made to reduce the causes of curly stitch defects are to perform machine maintenance and replace the lifeboat with a new one, stitches too edge is to double check the stitches after completion of production and make a standard stitch distance against the edge of the jumbo bag, stitches not according to the pattern is to double check the stitches after completion of production, broken stitches is to accept sewing operators who are experienced enough, jumping stitches is to provide education / coaching to operators to provide easier working methods.

OPTIMASI PROSES PRODUKSI PLASTIK PENYIMPANAN MAKANAN DI PT SANIPAK INDONESIA Panniarti Lubis, Dewi; Elsya Paskaria Loyda Tarigan
Computer Science and Industrial Engineering Vol 11 No 3 (2024): Comasi Vol 11 No 3
Publisher : LPPM Universitas Putera Batam

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33884/comasiejournal.v10i3.9092

Optimizing the production process is an activity carried out by production to increase efficiency, productivity and quality of each product produced. This activity is carried out by preventing the occurrence of several factors, one of which is waste in each process flow. The impact of waste that occurs on the production process flow is in the form of a decrease in the quality of the product being worked on. PT Sanipak Indonesia is a company engaged in the plastic manufacturing industry. One of them is food storage plastic, this company uses a Make to Order system. Food storage plastic production at PT Sanipak Indonesia experienced problems with product quality decreasing by up to 15% from the previous month. This results in many defective and wasted products in the storage warehouse, so that optimizing the production process does not run smoothly. The accumulation of defective products due to the production process that has been carried out causes losses for the company. Many products do not achieve good quality, this factor also occurs due to the minimal placement area for products that have been processed. Because production did not reach the desired quality target, overall improvements were made from the start to the end of the process. This research aims to find out how to reduce the waste that occurs so that the production process can run optimally. This research uses an analytical method based on the lean manufacturing approach with value stream mapping. To analyze waste, this research uses a fishbone diagram. The results obtained from periodic inspections carried out for 6 days were the occurrence of waste overproduction with the highest level of waste with a weight of 51.02%, and the lowest waste defect with a weight of 48.98%. This problem can be solved in several ways, one of which is repairing waste defects and waste overproduction by regularly calibrating machines or work tools according to SOPs, as well as replacing machines that are no longer suitable for reuse, and expanding storage warehouses by providing labels. product indication in each storage area. Based on the results of the Future State Mapping mapping carried out, a Process cycle efficiency value of 79.80% was obtained from 68.37%. These results showed that production had increased by 18.2%, which enabled the production process to optimize the production process again, so that the quality of the products produced increased again.

OPTIMASI KAPASITAS PRODUKSI PADA USAHA KECIL MENENGAH SARI RASA LESTARI Putri Edlin Solva; Elsya Paskaria Loyda Tarigan
Computer Science and Industrial Engineering Vol 11 No 4 (2024): Comasi Vol 11 No 4
Publisher : LPPM Universitas Putera Batam

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33884/comasiejournal.v11i4.9094

The production process is an activity that can produce quality products. The production process can determine whether the product is good or bad. when the process runs optimally, the results will be optimal and vice versa. Sari Rasa Lestari Small and Medium Business is an SME located in Taman Lestari, Batu Aji, Batam., and is a business that is engaged in producing noodles. The aim of the research is to find out the combination of products that can produce maximum profits. The method used in this research is Linear Programming, the simplex method. The results of the mathematical calculations in the first iteration are the value X1 = 1250kg with the value Zmax = IDR 2,125,000.00. , Because the Z value is still negative, iterations are carried out until the Z value is not negative, namely in the fourth iteration with the resulting values X1=1250kg, X2=1415.7kg, X3=761.7kg and X4=600 kg with a profit of Rp. 6,458,667 every month. Thus, the Sari Rasa Lestari Small and Medium Enterprises only produce x1, x2, x3 and x4 every month to get maximum profits

PERANCANGAN ULANG TATA LETAK FASILITAS PRODUKSI DI PT OSI ELECTRONICS Turnip, Krismawan; Elsya Paskaria Loyda Tarigan
Computer Science and Industrial Engineering Vol 11 No 4 (2024): Comasi Vol 11 No 4
Publisher : LPPM Universitas Putera Batam

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Presently, the facility layout at PT OSI Electronics Automotive Division is facing challenges. There is a significant distance between work stations, resulting in a longer material transfer distance and increased time for moving goods between work units. The objective of the performed research is to expedite the transfer of materials and propose recommendations for enhancing the layout of the firm's facilities. This will enable the company to decrease material handling expenses and minimise the distance required for material transfer. The stages conducted in this investigation encompass: Gathering data on the spatial separation of production lines, the quantity of workstations, and the dimensions of each production line. The acquired data was subsequently subjected to the Blocplan methodology for processing, followed by an examination of the optimisation outcomes, calculations, discussions, and ultimately drawing conclusions to determine the ultimate layout design. The most optimal plan for achieving efficiency and smoothness in the production process is layout 2, which is derived from software processing. Proposed schedule. The current configuration has a material handling distance of 68.46 metres, significantly shorter than the original layout's distance of 185.5 metres. Consequently, the overall distance for moving materials is reduced by 117.04 metres. The daily material handling cost for this proposed plan is IDR 1,288,760, which is lower than the material handling cost per metre in the initial layout, which was IDR 3,492,038. Consequently, the corporation can reduce its daily material handling expenses by IDR 2,203,278.

PENJADWALAN PREVENTIVE MAINTENANCE MESIN DRY VACUUM PUMP DI PT XYZ BATAM Sembiring Meliala, Ricky Yakub; Elsya Paskaria Loyda Tarigan
Computer Science and Industrial Engineering Vol 12 No 2 (2025): Comasie Vol 12 No 2
Publisher : LPPM Universitas Putera Batam

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33884/comasiejournal.v12i2.9731

In the manufacturing industry, ensuring a smooth production process is crucial for maintaining company performance. Machines play a vital role as a production factor that significantly affects the continuity of these processes. At XYZ Batam, frequent machine downtimes disrupt production targets. This study aims to determine the optimal machine maintenance intervals to reduce downtime. The Reliability Centered Maintenance II (RCM II) approach was applied using methods such as Failure Mode and Effect Analysis (FMEA), Mean Time to Failure (MTTF), and Mean Time to Repair (MTTR). The downtime data analyzed covers the period from April 2024 to September 2024. The results indicate that thermal overload repairs on dry vacuum pump no.1 and dry vacuum pump no.2 are the most frequent maintenance activities based on Risk Priority Number (RPN) calculations from the FMEA analysis. Preventive maintenance intervals for machines with the highest downtime rates were determined as follows: dry vacuum pump no.1 requires maintenance every 129,12 hours, and dry vacuum pump no.2 every 151,83 hours.

ANALISIS LINE BALANCING PADA PRODUKSI SETRIKA DI PT PHILIPS INDUSTRIES BATAM Dian Pratiwi; Elsya Paskaria Loyda Tarigan
Computer Science and Industrial Engineering Vol 12 No 2 (2025): Comasie Vol 12 No 2
Publisher : LPPM Universitas Putera Batam

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33884/comasiejournal.v12i2.9749

This study discusses line balancing in the production of irons at PT Philips Industries Batam, aiming to improve efficiency by addressing bottlenecks in the manufacturing process. The main focus is to optimize task distribution across workstations to minimize non-value-added time and enhance production line performance. Before the improvements, line efficiency was recorded at 94%, but there was still considerable idle time. Data collection was conducted through direct observation and time measurement of 18 operations using the Ranked Positional Weight (RPW) method. The analysis revealed that the implementation of Unique Device Identifier (UDI) labels led to increased operational times, particularly in operations 11, 15, and 18, causing workflow delays. After applying line balancing strategies, efficiency significantly improved from 67.97% to 96.23%. This study demonstrates that better task distribution can reduce production delays and support the achievement of operational targets. Key improvements include a reduction in balance delay and a smoother production flow, resulting in increased overall productivity. These findings highlight the importance of line balancing in optimizing manufacturing performance and provide valuable insights for industries seeking to enhance competitiveness through a more efficient production system.

Analisis Efektivitas Gas Turbine Generator pada PT Mitra Energi Batam Nur Azila; Elsya Paskaria Loyda Tarigan
JURNAL SURYA TEKNIKA Vol. 10 No. 2 (2023): JURNAL SURYA TEKNIKA
Publisher : Fakultas Teknik UMRI

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37859/jst.v10i2.6296

PT Mitra Energi Batam is one of the Gas Power Plants (PLTG) and regulates the electricity supply of Batam city with PT PLN-Batam. According to the tabulation of PT Mitra Energi Batam's production data from September 2022 to September 2023, the rolls-royce Gas Turbine Generator production engine has a downtime value of 805.60 hours. The purpose of the study is to find out the factors that cause high downtime and know how to minimize it. Using the proposed Overall Equipment Effectiveness method as a way to measure Losses due to production disruptions by taking six big loss and Fishbone diagrams to find the cause and effect of Losses that cause failure of machine or equipment operations. The results of the study of the highest OEE value in August 2023 were 98.54%, the lowest OEE value was in April 2023 which was 0%, the cause was severe damage to the power turbine blade which required engine replacement, but was constrained by the time of the engine spare delivery process. The six big Losses factor that contributed the most to the OEE value was idling minor stoppage with an average value of 8.83% and equipment failure Losses with an average value of 8.81%.

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