ENGINE ASSEMBLY PROCESS IMPROVEMENT:
CASE STUDY AT PT.XYZ
By Kenny Ardynata
11407008
BACHELOR’S DEGREE in
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
August 2018
Revision After Thesis Defense on 20 July 2018
Kenny Ardynata 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.
Kenny Ardynata
_____________________________________________
Student Date
Approved by:
Dr. Tanika Dewi Sofianti, S.T., M.T.
_____________________________________________
Thesis Advisor Date
Ir. Setijo Awibowo, MM
_____________________________________________
Thesis Co-Advisor Date
Dr. Irvan S. K., ST., MSc.
_____________________________________________
Dean Date
Kenny Ardynata ABSTRACT
ENGINE ASSEMBLY PROCESS IMPROVEMENT: CASE STUDY AT PT.XYZ
By Kenny Ardynata
Dr. Tanika Dewi Sofianti, S.T., M.T., Advisor Ir. Setijo Awibowo, MM, Co-Advisor
SWISS GERMAN UNIVERSITY
This thesis project is based on the case study at PT.XYZ especially in the car engine assembly line. The purpose are to increase the productivity and reduce the waste that occurs in the engine assembly line. Root cause analysis is used to develop the research methodology of this thesis project. To reach the objective of this thesis project, the author use current condition data to evaluate the value added, non-value added, and non-necessary value added time that included in each working element of engine assembly process. After analysis and discussion, there are 2 main working element that can be optimized such as tightening process and also the movement in taking parts for assembly the engine. By purposing tightening process improvement and also material grouping ideas, there will be some opportunities to optimize the work element that occurs at the engine assembly line from many aspects such as time and waste reduction that caused by the unnecessary processes.
Keywords: Assembly Line, Root Cause Analysis, Working Element, Optimization.
Kenny Ardynata
© Copyright 2018 by Kenny Ardynata
All rights reserved
Kenny Ardynata DEDICATION
I dedicate this thesis.
To Tuhan Yang Maha Esa for his infinite grace and blessings.
To my beloved parents that always support me wherever I am.
To all my amazing lecturers that have guide and motivate me in doing this thesis project.
To all great employees at PT.XYZ that already give new experiences and opportunities.
To all my incredible friends for their support and positive energy.
Kenny Ardynata ACKNOWLEDGEMENTS
First of all, I would like to be grateful to Tuhan Yang Maha Esa for his infinity grace and blessings for my entire life. I would like to say never ending thank you to my beloved parents for their full supports on me.
A huge thank you to all my lecturers in Swiss German University, especially for Dr.
Tanika Dewi Sofianti, S.T., M.T., and Ir. Setijo Awibowo, MM, Co-Advisor as my thesis advisor and co-advisor. That has put so much effort and time to lead me in passing all challenges in my thesis project.
It’s also an honor for me to gain new experiences and opportunities at PT.XYZ. A massive thank you to all employees and especially to Mr. Wahyu Ricardo that always guide and spare some times in a busy schedule for supervising me in creating this thesis.
Last but not least, friends always be there for you. Thank you to all my amazing friends that has accompany and always support me, especially for Steve Yuwono, Ronaldi, Felix Siswanto, Heinrich Putra and Juan Teguh that also has a chance to do the thesis project at PT.XYZ and all of my Industrial Engineering 2014 friends for the unforgettable amazing moments at Swiss German University.
Kenny Ardynata TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 9
LIST OF TABLES ... 11
CHAPTER 1 – INTRODUCTION ... 13
1.1. Background ... 13
1.2. Research Problems ... 14
1.3. Research Objectives ... 14
1.4. Significance of Study ... 14
1.5. Thesis Structure ... 14
CHAPTER 2 – LITERATURE REVIEW ... 15
2.1. Assembly ... 15
2.2. Productivity ... 15
2.3. Time Motion Study ... 16
2.3.1. Time Study ... 16
2.3.2. Motion Study ... 16
2.4. Root Cause Analysis ... 17
2.5. Lean Management ... 17
2.5.1. Transport ... 18
2.5.2. Inventory ... 18
2.5.3. Motion ... 19
2.5.4. Waiting ... 19
2.5.5. Over Processing ... 19
2.5.6. Over Production ... 19
2.5.7. Defect ... 20
2.5.8. Talent ... 20
2.6. 5S ... 20
2.7. Standard Operating Procedure ... 21
CHAPTER 3 – RESEARCH METHODS ... 23
3.1. Clarify the Problem ... 24
3.2. Breakdown the Problem ... 24
Kenny Ardynata
3.4. Analyze the Root Cause ... 25
3.5. Develop Countermeasures ... 26
3.6. Implement Countermeasures ... 27
3.7. Monitor Result and Processes ... 27
3.8. Standardize and Share Success ... 27
CHAPTER 4 – RESULTS AND DISCUSSIONS... 28
4.1. Clarify the Problem ... 28
4.2. Breakdown the Problem ... 28
4.3. Set the Target ... 32
4.4. Analyze the Root Cause ... 33
4.5. Develop Countermeasures ... 33
4.5.1. Tightening Process ... 33
4.5.2. Material Grouping ... 52
4.6. Implement Countermeasures ... 91
4.7. Monitor Result & Processes ... 91
4.8. Standardize and Share Success ... 92
4.9. User Acceptance Test ... 96
CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 101
5.1. Conclusions ... 101
5.2. Recommendations ... 101
REFERENCES ... 102
APPENDICES ... 103
APPENDIX A – Tightening Process ... 104
APPENDIX B – Material Grouping Working Instruction ... 113
CURRICULUM VITAE ... 139
