SERVICE TRAM MAINTENANCE IMPROVEMENT USING SIX SIGMA

• Main Author: DIRMAWAN (NIM: 29107129), AYEP
• Format: Theses
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/11895
• Institution: Institut Teknologi Bandung

Service Tram is an Aerial Tramways equipment in PT. XYZ as a transportation system of passengers and materials. Service Tram car moves on track cables in vertical distance of 750 meter and horizontal distance of 1500 meter. Safety and availability become the critical factor to the company to keep Service Tram as reliable transportation equipment. PTFI Service Tram 1 with average availability 90.6% and Service Tram 2 with average availability of 92.3%. Meanwhile availability target is 92.5% and 95% respectively. Total cost of maintenance material for both trams was USD 4.2 million for almost two years.<p>This Final Project objective is to improve Service Tram maintenance process that specifically to increase availability and reduce maintenance material cost. The improvement is using Six Sigma DMAIC (Define-Measure-Analyze-Improve-Control) methodology to identify and analyze problems for possible causes so that improvement plan can be established. Analysis is using tools of Fault Tree Analysis (FTA), Fishbone (Ishikawa) Diagram, Process Mapping, SIPOC (Suppliers-Inputs-Process-Outputs-Customers) and Impact/Effort Matrix.<p>The problems found related to availability are repeat failures causing Service Tram unplanned downtime. The events are analyzed for possible root causes. Related to material cost, there was excessive material cost due to repeat failures of materials, damage materials in the storage before use, materials didn't meet specifications, and excessive materials in the storage. The root causes found are related to method or procedures of maintenance practice, knowledge and skill, maintenance planning process and several issues of reengineering opportunity. The relevant solutions applied are creating maintenance procedures, training for the employees, improvement for several processes of maintenance planning and implementation, and reengineering. The solutions are managed in the implementation plan that involves key persons of Service Tram maintenance organization.