Analysis productivity on units water treatment production department IIIA PT. Petrokimia Gresik to minimize six big losses with OEE and FMEA methods

Abstract

In the era of rapid technological developments, industrial competition is getting tougher. The availability of machines during production, especially in the absence of breakdown or damage to production equipment is very important in the production process to maintain production continuity. One of the solutions to the problem of production facilities and to support increased productivity is the implementation of intensive evaluation and maintenance of production equipment. In this work, we study of such implementation in PT. Petrokimia Gresik. This type factory produces products from chemicals, where one of the raw materials is "demineralized water" which is produced from the "unit water treatment" of the Sulfuric Acid & Utilities Division III Production Department IIIA. It is known that in this unit water treatment the production process runs continuously for 14 hours a day. With a fairly high frequency of use, production machines need to have high-frequency maintenance that is in line with the potential for machine damage. This research will focus on the use of methods Overall Equipment Effectiveness (OEE) and Failure Mode and Effect Analysis (FMEA) to solve the problems found. The result of this study showed that the Overall Equipment Effectiveness (OEE) values obtained is 56,55%, which is below the standard value of the OEE classification. Machine availability is the main cause of damage with an 68% percentage value. The damage is due to the value of Equipment Failure/Breakdown which has the largest contribution in the six big losses with loss of total 390 Risk Priority Number (RPN) value. Failure with the largest RPN value is the leakage of SA pipe that has 168 RPN.