Analisis Loading Rate PKE (Palm Kernel Expeller) pada PT. Sari Dumai Sejati Menggunakan RCA (Root Cause Analysis)

Abstract

Penelitian ini bertujuan mengidentifikasi akar penyebab keterlambatan proses pemuatan Palm Kernel Expeller (PKE) di PT. Sari Dumai Sejati melalui pendekatan Root Cause Analysis (RCA). Latar belakang penelitian ini adalah tingginya suhu PKE pascaproduksi yang kerap melebihi batas aman 50 °C sehingga memerlukan proses trimming dan pendinginan sebelum pemuatan yang berdampak pada efisiensi operasional dan waktu tunggu kapal (laytime). Metode penelitian bersifat kualitatif-deskriptif dengan pengumpulan data primer melalui observasi lapangan dan wawancara semi-terstruktur dengan operator gudang serta data sekunder berupa laporan loading rate dan catatan pemeliharaan mesin. Analisis RCA dimulai dengan penyusunan diagram fishbone untuk mengkategorikan faktor penyebab ke dalam aspek material, mesin, metode, dan faktor lingkungan (Mother Nature); selanjutnya dilakukan validasi akar masalah melalui tabel RCA dan pemetaan tindakan menggunakan metode 5W1H. Hasil analisis fishbone mengungkap bahwa kegagalan cooling conveyor menyebabkan suhu PKE tetap tinggi, keseringan stoppage pada conveyor dan elevator serta belt longgar menghambat laju pemuatan, boiler yang tidak optimal mempengaruhi sirkulasi udara dalam gudang, dan hujan memaksa penghentian proses loading sehingga PKE menjadi basah. Tabel RCA menegaskan faktor material (conveyor rusak), faktor mesin (conveyor/elevator/boiler bermasalah), dan faktor cuaca (hujan) sebagai akar penyebab utama. Metode 5W1H merinci skenario gangguan suhu, lokasi analisis gudang PKE, waktu penelitian pada Juli 2024, narasumber, dan proses observasi. Berdasarkan temuan tersebut, direkomendasikan penjadwalan pemeliharaan berkala serta perbaikan cooling conveyor, penggantian belt elevator, peningkatan kapasitas loader, optimalisasi boiler, dan penyediaan shelter loading agar proses tidak terhambat hujan. Implementasi rekomendasi ini diharapkan mempercepat pendinginan PKE, mengurangi delay loading, meningkatkan efisiensi operasional, mendukung kepatuhan terhadap standar mutu ekspor, dan memperkuat reputasi perusahaan di pasar internasional.

This study aims to identify the root causes of delays in loading Palm Kernel Expeller (PKE) at PT Sari Dumai Sejati by applying a Root Cause Analysis (RCA) approach. The investigation is motivated by recurring instances of PKE temperatures exceeding the safe threshold of 50 °C after production, necessitating additional trimming and cooling steps that adversely affect operational efficiency and vessel laytime. Employing a qualitative‑descriptive methodology, primary data were collected through on‑site observations and semi‑structured interviews with warehouse operators, while secondary data comprised loading rate records and machinery maintenance logs. The RCA process began with the creation of a fishbone diagram to categorize potential causes into material, machine, method, and environmental (Mother Nature) factors, followed by a validation table to confirm actual root causes and a 5W1H mapping to outline corrective actions. Analysis revealed that cooling conveyors frequently malfunctioned, preventing effective temperature reduction; conveyors and elevators often experienced stoppages and loose belts hindered loading continuity; boilers operated below optimal capacity, compromising warehouse air circulation; and loading operations were suspended during rainfall, causing PKE moisture issues. The RCA table substantiated that conveyor failures, machine malfunctions (conveyors, elevators, boilers), and adverse weather were the primary contributors to loading delays. The 5W1H framework detailed the what, where, when, why, who, and how of these disruptions. Based on these findings, we recommend implementing a regular maintenance schedule and repairing cooling conveyors, replacing elevator belts, enhancing loader capacity, optimizing boiler performance, and installing protective shelters over loading areas to mitigate weather impacts. Adoption of these measures is expected to expedite PKE cooling, minimize loading delays, improve operational efficiency, ensure compliance with export quality standards, and reinforce the company’s reputation in international markets.