Analisis efektivitas penggunaan alat bantu pengangkatan ply pada mesin building pt AST

Saputra, Adi (2024) Analisis efektivitas penggunaan alat bantu pengangkatan ply pada mesin building pt AST. Bachelor thesis, Universitas Pelita Harapan.

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Abstract

Industri manufaktur menjalankan usahanya untuk mengolah bahan baku menjadi menjadi produk melalui serangkaian proses produksi. Proses produksi yang dijalankan pada departemen building PT AST yaitu proses assembly green tire. Pada proses ini terdapat aktivitas penggantian material yang dilakukan secara manual dengan mengangkat roll atau gulungan ply (material) ke badan mesin, yang dapat menimbulkan risiko cedera pada operator. Dalam upaya mengurangi dan menghilangkan peluang cedera tersebut, departemen engineering bekerja sama dengan departemen building sebagai user telah merancang dan membuat alat bantu pengangkatan ply. Alat bantu ini berhasil dibuat dan diujicobakan pada bulan Mei 2023, namun tidak digunakan secara lanjut dalam proses produksi. Selanjutnya dilakukan analisis efektivitas penggunaan alat bantu pengangkatan ply berdasarkan produktivitas alat, waktu baku, serta tingkat risiko cedera yang dihasilkan sebelum dan sesudah menggunakan alat bantu berdasarkan nilai REBA, dan Lifting Index. Hasil uji t berpasangan menunjukkan produktivitas setelah menggunakan alat bantu tidak berbeda signifikan dari sebelumnya. Waktu baku proses penggantian material setelah menggunakan alat bantu lebih lama sebesar 122,148 detik dari waktu sebelumnya selama 74,37 detik. Namun nilai waktu baku tersebut tidak mampu memengaruhi nilai produktivitas, karena rasio waktu aktivitas ini hanya 2,3% dan 3,8% dari 100% waktu kerja operator dalam satu shift. Alat bantu pengangkatan ply mampu menurunkan tingkat risiko cedera berdasarkan REBA dari risiko sangat tinggi (11 poin), ke risiko medium (7 poin), dan berhasil menghilangkan risiko cedera punggung berdasarkan nilai lifting index yang turun dari 2,56 atau risiko tinggi ke 0 atau tanpa risiko. Kesimpulannya alat bantu pengangkatan ply ini sudah efektif secara fungsional karena mampu mengurangi potensi cedera pada operator dan dapat diterapkan penggunaannya di departemen building/The manufacturing industry carries out its business to process raw materials into products through a series of production processes. The production process conducted in the building department of PT AST involves the assembly of green tires. Within this process, there's a manual material replacement activity manual that entails lifting rolls or ply rolls (materials) onto the machine body, posing a risk of injury to the operator. To address this issue, the engineering department collaborated with the building department as users to design and create a ply lifting aid. This aid was successfully constructed and tested in May 2023 but wasn't subsequently utilized in the production process. Subsequently, an analysis was conducted on the effectiveness of the ply lifting aid to determine its productivity value and impact, standard time, as well as the injury risk value generated before and after using the aid based on REBA (Rapid Entire Body Assessment) and Lifting Index values. Paired t-test results indicated that the productivity after using the lifting aid did not significantly differ from the previous productivity. The standard time for the material replacement process post-aid usage increased by 122.148 seconds from the earlier time of 74.37 seconds. However, this standard time value didn't impact productivity significantly, given that the activity's time ratio was only 2.3% and 3.8% of the operator's total shift working time. The ply lifting aid managed to decrease the risk level according to REBA from very high risk (11 points) to medium risk (7 points), successfully eliminating the risk of back injury based on the Lifting Index, dropping from 2.56 (high risk) to 0 (no risk). In conclusion, the ply lifting aid has functioned effectively and can be implemented within the building department.

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