Peci

Problem solving
Improvement
PRODUCTION ENGINEER 2019
How to Improve Actual Peci Capacity
▪ Peci production Actual Capacity Standard
▪ Improvement of Peci Production Capacity Standard
 Peci Production Actual Capacity Standard
Machine Capacity
Core Peci Item
Setting Stroke Time per Shift per Month KESIMPULAN DATA KAPASITAS MESIN LEAN
Peci 01 Polos 13 Hz 1.25 sec 15,206 1,140,480
Desember 2018
Peci 02 Polos 16.1 Hz 1.27 sec 14,967 1,122,520

Peci 03 Polos 16 Hz 1.37 sec 27,749 2,081,168

Peci 04 Polos 17,95 Hz 1.26 sec 30,171 2,262,857 • Kapasitas Peci Polos : 13.325.717 perbulan
Peci 05 Polos 24.5 Hz 1.25 sec 30,413 2,280,960
• Kapasitas Peci Lis : 12.796.418 perbulan
Peci 06 Polos 24 Hz 1.28 sec 29,700 2,227,500

Peci 07 Polos 9.2 Hz 1.29 sec 29,470 2,210,233 • Kapasitas Peci Emboss : 3.207.240 perbulan
Peci 01 Lis 13 Hz 1.04 sec 17,135 1,285,096 • Kapasitas Peci Crepe : 3.171.278 perbulan
16.1 Hz 1.27 sec 14,031 1,052,362
Peci 02 Lis
16 Hz 1.37 sec 26,015 1,951,095
• Kapasitas Peci lem tngh: 1.931.352 perbulan
Peci 03 Lis
Peci 04 Lis 18,58 Hz 1.21 sec 29,455 2,209,091 • Kapasitas Peci 2warna : 5.181.660 perbulan
Peci 05 Lis 24.5 Hz 1.25 sec 28,512 2,138,400
24 Hz 1.28 sec 27,844 2,088,281
Peci 06 Lis
9.2 Hz 1.29 sec 27,628 2,072,093
• Untuk Peci Lis terdapat penurunan kapasitas sebesar
Peci 07 Lis
Peci 04 Emboss 18 Hz 1.29 sec 22,102 1,657,674 3.97% thd Kapasitas jika jalan polos
Peci 07 Emboss 9,29 Hz 1.38 sec 20,661 1,549,565 • Untuk Item khusus yg tidak dapat dikerjakan di semua
Peci 01 9.3 Hz 1.51 sec 11,015 826,093
Crepe
11,25 Hz 1.80 sec 9.240 693.000
mesin:
Peci 02 Crepe
Peci 04 Crepe 12.56 Hz 1.51 sec 22,029 1,652,185 • Crepe aktual penurunan kapasitas 28%
Peci 01 Lem Tengah 11,07 Hz 1.23 sec 13,522 1,014,146
• Emboss aktual penurunan kapasitas 25%
Peci 02 Lem Tengah 15,07 Hz 1.36 sec 12,229 917,206

Peci 03 2 warna 14.06 Hz 1.54 sec 20,057 1,504,286

• Lem tengah aktual penurunan kapasitas 12%
Peci 04 2 warna 17.85 Hz 1.27 sec 24,321 1,824,094 • Cetak 2 warna actual penurunan kapasitas 17%
Peci 05 2 warna 24.5 Hz 1.25 sec 24,710 1,853,280
 Peci Productivity Actual vs 13M March Order Analysist
Komposisi Order Peci Maret 2019 • Not Possible for Non Overtime Planing
Production Planing vs Order Lead Time • Optimum with 3 days Overtime at 3,10,
Peci Crepe,
Peci Embos, 1,210,000, 620 17 Sunday Overtime but extra
200,000, 2% 9%
Peci Polos,
600 supervisory on Peci 5 & 6 (zero safety
Peci 2 warna, 5,849,000, 580 margin). Not Recomended
706,000, 5% 44%
560
• 5 days Sunday Overtime
540
(@3,10,17,24,30): Recomended
520
Peci 1 : 11% (59 hours)
500
Peci 2 : 13% (66 hours)
480
460
Peci 3 : 14% (72 hours)
Peci Lis,
5,222,505, 440
Peci 4 : 12% (64 hours)
40% Peci1 Peci2 Peci3 Peci4 Peci5 Peci6 Peci7 Peci 5 : 7% (40 hours)
Peci Polos Peci Lis Peci 2 warna Peci Embos Peci Crepe Non Lembur Lembur 3hari Lembur 5hari Order Peci 6 : 7% (40 hours)
Peci 7 : 10% (52 hours)

Tanggal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Peci 1 33,045 33,045 33,045 33,045 33,045 33,045 33,045 33,045 33,045 33,045 33,045 33,045 51,405 51,405 51,405 51,405 51,405 51,405 51,405 51,405 45,618 45,618 45,618 45,618 45,618 45,618 45,618

Peci 2 27,720 27,720 27,720 27,720 27,720 27,720 27,720 27,720 27,720 27,720 27,720 27,720 18,211 42,093 42,093 42,093 42,093 42,093 42,093 42,093 44,901 44,901 44,901 44,901 44,901 44,901 44,901

Peci 3 60,171 60,171 60,171 60,171 22,870 78,045 78,045 78,045 78,045 78,045 78,045 78,045 78,045 78,045 78,045 78,045 78,045 78,045 78,045 78,045 83,247 83,247 83,247 83,247 83,247 83,247 83,247

Peci 4 66,306 33,694 72,963 72,963 66,087 66,087 66,087 66,087 66,087 66,087 66,087 88,365 88,365 88,365 88,365 88,365 88,365 88,365 88,365 88,365 90,513 90,513 90,513 90,513 90,513 90,513 90,513 66,335

Peci 5 74,130 74,130 74,130 74,130 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 85,536 91,329 91,329 91,329 91,329 91,329 91,329 91,329 91,329

Peci 6 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100 89,100

Peci 7 61,983 38,017 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 82,884 88,410 88,410 88,410 88,410 88,410 88,410 88,410 88,410
 Productivity Actual Improvement

Productivity Actual Improvement:

Stable Machine Capacity in every machine
Good Productivity Margin in every machine
Machine Breakdown Downtime Margin in every machine

IMPROVEMENT :

▪ Stable Machine Capacity in every Machine :

Locking Capacity Project
▪ Good Productivity Margin in every Machine:
Push Reject to Minimum
Push Downtime to Minimum
▪ Machine Breakdown Downtime Margin in every machine
Machine Breakdown Modelling System
Push Machine Breakdown Margin to Minimum
IMPROVEMENT
Peci PT. Maesindo Indonesia
Locking Capacity Project
• Machine Capacity based on Potentiometer,
Capacity ramping up linear with potentiometer
knob turning (the value of resistance).
• Potentiometer accessible for operator with non
managerial skill, production plan knowledge, and
productivity.
• Machine capacity is foundation of production
plan, productivity for production management
system.

• Potentiometer accessible for operator still but not

the machine capacity (value of the resistance),
it’s accessible for production management
system and planner.
• The Electronics Board can lock (8 preset or
below) capacity setting/ value of resistance by
microcontroller reading the potentiometer knob
turning
 Push Reject to Minimum
Tawaran Solusi
No. Tipe Reject Detail Reject Analisa Penyebab PIC
According to KPI, Mean Jangka Pendek Jangka Panjang
Peci Reject 1 Setting Polymer Setting manual dan dicek ke bahan - Digital Printing
2 Reject Approve Warna Beda kecapatan beda warna - Digital Printing
3 Rijek Printing 2 Warna Logo Setting refrensi tiap untit cetak - Digital Printing
• Peci Polos : 1.5% 4 Setting warna Lis Setting cetak dan potongan Floating DPI Digital Printing
• Peci Lis : 2.5% 5 Reject Berhenti Roll Anilog tdk tercelup dan kering Istirahat gantian Auto Splacing

• Peci Embos : 3% 6 Lipat Rongga ke Rapat setting drum pelipat - Rubah model Sepatu
7 Rijek Pelipat Pelipat Litho (sirip) Litho lompat dari sirip - Roll alur spt Masker
• Peci Crepe : 3.4% 8 Pengarah Litho (litho melet) - Roll alur spt Masker
Litho geser
• Peci Lem Tngh: 3.2%
9 Jubel Conveyor Penumpuk Conveyor naik lebih pelan dari mesin Speed Control -
• Peci 2warna : 3.8%
Rijek Jubel
10 Jubel Litho terbelit Landasan Permukaan landasan tdk halus Ganti landasan Pelubang Litho baru

11 Jubel Litho terbelit Pisau Litho putus Setting Roll AutoTension

12 Piringan Aus/ Rusak Piringan termakan gesekan kertas Ganti piringan Magnetic Noozle
Pointing Lem di akhir garis Respon lambat dan tekanan balik Beri Valve di Pressure
13 Magnetic Noozle
Rijek Lengket noozle Pressure Tank Tank

Lem Tembus Meltblown

14 Nozzle kurang tipis Gunakan Piringan Magnetic Noozle
noozle

Kalibrasi Roll-roll
15 Litho Putus Setting brake , roll pengarah tdk center AutoTension
pengarah
Rijek Tension
Roll besar tension tidak stabil karena Ganti brake kapasitas
16 Litho geser karena Roll besar AutoTension
melebihi kapasitas brake lebih besar
 Push Downtime to Minimum
• According Lean Observation, Mean Downtime Peci 50% (3.3 jam)
Solusi
Waktu
No. Downtime Analisa Penyebab
(min) Jangka Pendek Jangka Panjang

1 Setting Polymer baru/2 warna 30 Ganti OP, skill operator Digital Printing
2 Ganti Bahan 22 Bahan habis Auto Splacing
Bersih-bersih, Isi Laporan, Persiapan
3 21 Persiapan pulang Mi-Scada
Pulang

ScoreBoard Voice
4 Idle (ngobrol, jalan, Sholat, Toilet, dll..) 20 Sikap Pribadi Training
Assistance

Ganti tinta, bersihkan bak, ambil tinta,

5 16 Ganti OP Digital Printing
setting tinta

Order Note
6 Briefing 16 Koordinasi Pekerjaan ditempel sblm Mi-Scada
awal shift
7 Setting dan Persiapan Produksi 15 Ganti shift Overlap shift

Buat
Lem jauh tidak boleh disimpan penampungan Central Distribution
8 Mengambil Lem 15
di area produksi kapasitas 1shift di Pump
dalam mesin

9 Setting Busa Penekan Lipatan 11 Fragile, tidak kokoh Modifikasi Desain

10 Perbaiki Lipatan 10 Muncul Reject Lipatan AutoTension

Bahan belum tersedia di dekat Siapkan Bahan

11 Ambil Bahan 10 Auto Splacing
mesin sebelum awal shift

12 Setting Cutter 5 Setting cutter tdk pas Penggeser cutter

13 Litho berjubel 3 Tarikan bermasalah Piston Press Roll

14 Bahan putus terlilit roll, pisau, dll 3 Setting Tension tidak pas AutoTension
 Machine Breakdown Margin

Theory Capacity = Capacity per shift * Productivity Margin per machine * Breakdown Margin per machine

What is Machine Breakdown Margin?

• Breakdown Margin for Capacity Backup if the machine is broken-down and need to be production off
for Maintenance repairment
• Could be Performance Indicator for Maintenance to push the Minimum Margin

How to modeling Machine Breakdown Margin per machine?

How to Improve Machine Breakdown Margin to Minimum?

THANK YOU
Production Engineer 2019