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Sulaeman, Benyamine
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Earth & Planetary Sciences Electrical & Electronics Engineering Energy Engineering Environmental Science Industrial & Manufacturing Engineering

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Implementation of Non-Destructive Radiographic Testing for Welding Defect Inspection on Heat Exchanger Project DXXXX at PT XYZ Ismawaty, Marizka Putri; Herwanto, Dene; Sumitra, Naufal Rabbani; Sulaeman, Benyamine
Jurnal Serambi Engineering Vol. 11 No. 1 (2026): Januari 2026
Publisher : Faculty of Engineering, Universitas Serambi Mekkah

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Welding in the heat exchanger fabrication process is a critical stage that determines structural integrity and operational safety, but internal defects are still often found that cannot be detected visually. This study was conducted to identify the type of welding defect in the Heat Exchanger Project DXXXX and analyze the causative factors based on ASME Section V and VIII standards. The research approach uses a descriptive qualitative method through direct observation of the welding process, Radiography Test documentation, and interviews with Quality Control personnel during field work practice activities. The results showed that out of 279 radiographic films examined at 29 connection points, 31 defects were found consisting of two main types, namely slag inclusion and porosity. Slag inclusion defects are the most dominant finding and are influenced by human factors and work methods, while porosity defects are mainly caused by inaccuracies in methods related to the regulation and use of shielding gas. These findings indicate that inconsistencies in welding procedures, suboptimal material preparation, and inconsistent process control contribute significantly to the occurrence of defects. This study concludes that the Radiography Test is able to provide a comprehensive picture of the quality of weld joints and the defect patterns that occur in heat exchanger fabrication. Recommendations include improving operator competence, reviewing welding procedures according to ASME standards, improving QC supervision, and regular calibration of welding equipment to minimize the recurrence of defects in the welding process in the future
Quality Control Analysis of Side Member Assy RR Floor Product Using the Statistical Quality Control Method at PT XYZ Sulaeman, Benyamine; Fransisca Debora; Dewi Ayu Lestari; Marizka Putri Ismawaty; Dian Andini
Jurnal Serambi Engineering Vol. 11 No. 2 (2026): April 2026
Publisher : Faculty of Engineering, Universitas Serambi Mekkah

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Quality control is a critical aspect of the manufacturing industry to ensure that every product meets the specified requirements. PT XYZ, as an automotive component manufacturer, faces the problem of a high number of defective products in the Side Member Assy RR Floor component. This study aims to analyze the quality control process using the Statistical Quality Control (SQC) method with the Seven Tools approach. The research methods include data collection through observation and documentation, followed by analysis using tools such as control charts, checksheets, histograms, Pareto diagrams, scatter diagrams, fishbone diagrams, and flowcharts. The results show that the dominant type of defect is spatter, accounting for 83.7% of total defects. Control chart analysis indicates that the process is not fully under control, as evidenced by data points falling outside the control limits. Fishbone analysis reveals that the main causes of defects originate from non-standardized work methods and insufficient operator skills. As a concrete improvement measure, Standard Operating Procedure (SOP) documents and Visual Inspection Checklist forms were developed. This study provides a tangible contribution by assisting the company in improving product quality and systematically reducing defect rates.
Maintenance Strategy Optimization for Auto Assembly Lever Holder Machine using Black-Box Approach Lestari, Dewi Ayu; Herwanto, Dene; Sulaeman, Benyamine; Andini, Dian
Jurnal Serambi Engineering Vol. 11 No. 2 (2026): April 2026
Publisher : Faculty of Engineering, Universitas Serambi Mekkah

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A manufacturing company that produces automotive components has recorded the auto assembly lever holder machine as the automatic machine with the highest failure frequency throughout 2024. This condition disrupts the smooth operation of the production process and results in decreased production output, often failing to meet company targets. In response to this situation, this study was conducted to estimate the reliability and optimize the maintenance policy of the auto assembly lever holder machine. The study employed a black-box failure modelling approach. A probabilistic approach was also applied by utilizing Weibull distribution properties to estimate system reliability and optimize the machine's maintenance strategy. Based on the conducted analysis, the machine has a cumulative failure probability of over 50% at 300 operating hours, indicating a high tendency for failure. The optimization of the maintenance policy considered both the periodic replacement policy and repair count policy. The optimized maintenance policy for the auto assembly lever holder machine recommends preventive maintenance every 522.305 hours at a lower maintenance cost of Rp 20,680 per hour. Replacement actions are only applied to the critical component. These findings provide a data-driven basis for optimizing machine maintenance strategies and reducing unplanned downtime, thereby improving machine reliability and productivity.
Co-Authors Andini, Dian Dene Herwanto Dewi Ayu Lestari Dewi Ayu Lestari Dian Andini Fransisca Debora Ismawaty, Marizka Putri Marizka Putri Ismawaty SUMITRA, NAUFAL RABBANI