By
Adiva Nindito 11407035
BACHELOR’S DEGREE in
DEPARTMENT OF INDUSTRIAL ENGINEERING
FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
July 2018
Revision after Thesis Defence on 19th of July 2018
Adiva Nindito STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Adiva Nindito
_____________________________________________
Student Date
Approved by:
Anton Royanto Ahmad, S.T., M.Sc.
_____________________________________________
Thesis Advisor Date
Dr. Tanika Dewi Sofianti, S.T., M.T.
_____________________________________________
Thesis Co-Advisor Date
Dr. Irvan S. Kartawiria, S.T., M.Sc.
_____________________________________________
Dean Date
Adiva Nindito ABSTRACT
THE IMPLEMENTATION OF A TOOL MANAGEMENT SYSTEM FOR RIVETING EQUIPMENT IN PT. XYZ
By
Adiva Nindito
Anton Royanto Ahmad, S.T., M.Sc., Advisor Dr. Tanika Dewi Sofianti, S.T., M.T., Co-Advisor
SWISS GERMAN UNIVERSITY
PT. XYZ is an electrical company specializing in the production of electrical panels.
Rivet guns are a main production tool constantly utilized in the production processes of company. The company’s rivet guns are constantly taken in for maintenance, and a method to reduce the amount of failures was desired. The company itself lacks current and historical data along with an identification scheme for the company’s rivet guns.
An implementation of preventive maintenance was desired, but was deemed to be an unrealistic task. As a result, the research focuses on developing an aid for the company to formulate and implement preventive maintenance strategies. A tool management system was decided to be an effective solution. The development process included research on the company’s current condition, the collection of historical data, and the coding of software. The result was a tool management system capable of storing data on all the rivet guns in the company, recording historical data during recording processes, displaying repair histories, displaying notifications for preventive maintenance dates, and displaying metrics meant for performance evaluation.
Keywords: Preventive maintenance, tool management system, Waterfall Methodology
Adiva Nindito
© Copyright 2018 by Adiva Nindito All rights reserved
Adiva Nindito DEDICATION
The author dedicates this work to his family, friends, and all the teachers and lecturers that have taught him in the past
Adiva Nindito First, the author would like to express his gratitude to God for his guidance and help during the entire process of this thesis project.
The author would like to express his deepest gratitude to Mr. Anton Royanto Ahmad and Dr. Tanika Dewi Sofianti for their constant help and advice through the creation of this thesis. Their knowledge and experience greatly benefitted the author during difficult times, and gave him guidance during periods where the author lacked direction.
Their willingness to listen to thesis-related problems and solve them will always be appreciated.
The author would to thank PT. XYZ for their willingness and readiness to provide an opportunity to use their factory for thesis research purposes. Mr. Adi Widiadi was extremely open to the ideas put forth by the author, and was willing to provide a suitable thesis problem for research. His support allowed the author to develop and test a program suitable for solving the research problem. The maintenance staff were also a great help during data collection, as they supported and accepted the introduced processes without much hassle. Their geniality was an appreciated notion.
The author would like to thank his family for their support during the thesis writing period. Their assurances and understanding allowed for a relatively smooth writing process. Finally, the author would like to thank Niko, Nicky, Daniel, Rezky, Kenny, Steve, Andreas, Helen, Fathur, Rihan, Wilson and Felix for the times spent working on the thesis together. Their presence and support was greatly appreciated.
Adiva Nindito TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 11
LIST OF TABLES ... 13
CHAPTER 1 - INTRODUCTION ... 14
1.1 Background ... 14
1.2 Research Problems ... 15
1.3 Research Objectives ... 16
1.4 Significance of Study ... 16
1.5 Research Questions ... 16
CHAPTER 2 - LITERATURE REVIEW ... 18
2.1 Lean Manufacturing ... 18
2.1.1 Seven Wastes ... 19
2.1.2 5S ... 19
2.2 Maintenance ... 20
2.2.1 Preventive Maintenance ... 20
2.2.2 Corrective Maintenance ... 22
2.2.3 Total Productive Maintenance ... 23
2.3 Mean Time Between Failure and Mean Time To Repair ... 25
2.4 Waterfall Method ... 26
2.5 Unified Modeling Language ... 27
2.5.1 Use Case Diagram ... 28
2.5.2 Sequence Diagram ... 29
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CHAPTER 3 - RESEARCH METHODOLOGY ... 32
3.1 Requirements Phase ... 33
3.1.1 Problem Identification ... 33
3.1.2 Current State Analysis ... 33
3.1.3 Literature Review ... 33
3.1.4 Consultation ... 34
3.1.5 Program Requirements ... 34
3.2 Analysis Phase ... 34
3.2.1 Data Requirements ... 34
3.2.2 Technology Requirements ... 35
3.2.3 Work Scope ... 35
3.3 Design Phase ... 35
3.4 Coding Phase ... 35
3.5 Testing Phase ... 36
3.6 Acceptance Phase ... 36
CHAPTER 4 - DESIGN & DEVELOPMENT ... 37
4.1 Requirements Phase ... 37
4.1.1 Problem Identification ... 37
4.1.2 Current State Analysis ... 38
4.1.3 Current Repair Workflow ... 40
4.1.4 Literature Review ... 42
4.1.5 Consultation ... 42
4.1.6 Program Requirements ... 43
4.2 Analysis Phase ... 46
4.2.1 Data Requirements ... 47
Adiva Nindito
4.2.1.2 Physical Indicator ... 49
4.2.1.3 Data Fields ... 51
4.2.1.4 Recording Medium ... 51
4.2.2 Technological Requirements ... 53
4.2.3 Work Scope ... 53
4.2.3.1 Log-in ... 54
4.2.3.2 Dashboard ... 54
4.2.3.3 Classification Database ... 55
4.2.3.4 Tool Database ... 55
4.2.3.5 Repair Pages ... 56
4.3 Design Phase ... 57
4.3.1 Repair Workflow Restructuring ... 57
4.3.2 Software Description ... 65
4.3.3 Use Case Diagram ... 69
4.3.4 In-Program Flow Charts ... 71
4.3.5 Entity Relationship Diagram ... 78
CHAPTER 5 - PROGRAM DEVELOPMENT ... 80
5.1 Historical Data Collection ... 80
5.1.1 Prerequisites Installation ... 80
5.1.2 Log Sheet Recording ... 81
5.2 Program Breakdown ... 82
5.2.1 Login ... 82
5.2.2 Dashboard ... 83
5.2.3 Brand Database ... 84
5.2.4 Type Database ... 86
Adiva Nindito
5.2.6 Tool Database ... 88
5.2.7 Repair Processes ... 89
5.2.7.1 Request Repair ... 89
5.2.7.2 Repair Process ... 91
5.2.7.3 Finish Repair ... 93
5.2.7.4 Repair History ... 93
5.3 Work Instructions ... 94
5.4 Program Configuration ... 95
CHAPTER 6 - TESTING PHASE ... 99
6.1 Test Description ... 99
6.2 Test Execution ... 100
6.3 Results and Analysis ... 101
6.3.1 Test Results ... 101
6.3.2 Analysis of Test Results ... 102
6.4 Discussed Benefits ... 104
6.5 Discussed Concerns ... 106
CHAPTER 7 - CONCLUSION AND RECOMMENDATIONS ... 108
7.1 Conclusion ... 108
7.2 Recommendations for Future Research ... 109
BIBLIOGRAPHY ... 110
APPENDIX A - USER ACCEPTANCE TEST ... 113
APPENDIX B - SOFTWARE REQUIREMENT SPECIFICATION ... 116
APPENDIX C - WORKING INSTRUCTIONS ... 117
CURRICULUM VITAE ... 118
