Increasing Bead Productivity with Wire Counting Tools Using Design of Experiment (DOE) Methods And Investment Feasibility at PT. RZ

Arief Suwandi (Universitas Esa Unggul)
Meli Rani (Universitas Esa Unggul)

JURNAL Al-AZHAR INDONESIA SERI SAINS DAN TEKNOLOGI
Vol. 11 No. 3 (2026): September 2026

Bead is a tire component which is formed through a let off bobbin process, used as a stand so that the bobbin can rotate and wire can be used to make beads. The 2021 Bead Forming area KPI did not reach the target. The Bead Forming Machine stops during stock taking because it is still manual. The aims of this research are to analyze the design of a wire counting device using the DOE method and to analyze the feasibility of investment so that the use of wire can be monitored in real time, speeding up stock taking and preventing the machine from stopping. Optimal results with the smallest error value using a roll encoder of around 10 and 20 pulses which produce an error value of 0.0050 (0.5%). The investment feasibility results show that the required investment cost for a wire counter is 81,000,000 IDR. While the loss when the machine stops is 131,221,200 IDR for 1 year. Reducing error values ​​can increase KPI achievements with an initial value of 2.2% dropping to 0.5%, with the help of an automatic stock taking wire counter on the monitor.