Identifikasi Faktor Penyebab Kecacatan Lembaran Karton pada Mesin Corrugator PT XYZ Dengan Metode Fault Tree Analysis

Abstract

Persaingan industri manufaktur yang semakin ketat menuntut perusahaan untuk menjaga kualitas produk agar mampu memenuhi standar produksi dan kebutuhan pelanggan. PT XYZ mengalami permasalahan tingginya kecacatan lembaran karton pada mesin corrugator dengan tingkat cacat rata-rata sebesar 4,92%, melebihi batas toleransi perusahaan sebesar 2%. Metode yang digunakan dalam penelitian ini adalah Fault Tree Analysis(FTA). FTA digunakan untuk menelusuri akar penyebab kegagalan berdasarkan hubungan antar kejadian. Hasil penelitian menunjukkan bahwa faktor manusia disebabkan oleh kelelahan operator dan kurangnya pelatihan SOP, faktor mesin disebabkan oleh kurangnya perawatan dan ketidaksinkronan sistem penggerak, faktor material dipengaruhi kualitas perekat dan kondisi penyimpanan bahan baku, sedangkan faktor metode berkaitan dengan SOP yang belum distandarisasi. Selain itu, ditemukan bahwa perbedaan prosedur kerja antar shift turut memengaruhi kualitas hasil produksi karton. Berdasarkan hasil analisis, perusahaan perlu melakukan perbaikan melalui pelatihan operator, penjadwalan kerja yang lebih baik, perawatan mesin secara rutin, pengawasan kualitas material, dan standarisasi SOP. Implementasi perbaikan tersebut diharapkan dapat menurunkan tingkat kecacatan lembaran karton hingga berada di bawah batas toleransi perusahaan dan meningkatkan produktivitas produksi.

Increasingly intense competition in the manufacturing industry requires companies to maintain product quality in order to meet production standards and customer demands. PT XYZ is facing a problem of high defect rates in corrugated cardboard sheets produced by the corrugator machine, with an average defect rate of 4.92%, exceeding the company’s tolerance limit of 2%. The method used in this study is Fault Tree Analysis (FTA). FTA was employed to trace the root causes of failures based on the relationships between events. The results showed that human factors were caused by operator fatigue and insufficient SOP training, machine factors were caused by inadequate maintenance and unsynchronized drive systems, material factors were influenced by adhesive quality and raw material storage conditions, while method factors were related to non-standardized SOPs. In addition, differences in work procedures between operator shifts were found to affect the quality of cardboard production results. Based on the analysis results, the company needs to implement improvements through operator training, better work scheduling, routine machine maintenance, material quality control, and SOP standardization. The implementation of these improvements is expected to reduce the defect rate of cardboard sheets to below the company’s tolerance limit and improve production productivity.