IMPROVEMENT OF PRODUCTION PROCESS PRETREATMENT USING LIFE CYCLE COST ANALYSIS AND DMAIC METHODOLOGY IN PT ABC

• Main Author: Setyo Yulianto, Fungki
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/79306
• Institution: Institut Teknologi Bandung

PT ABC is a motorcycle market leader in Indonesia. One of the goals of PT ABC captured by developing in sustainability company. PT ABC strongly supports the DEF group sustainability aspiration framework 2023, especially the greenhouse gases (GHG) reduction pillar, and makes a real contribution to the achievement of the Indonesian Government’s Sustainability Development Goals (SDGs) and nationally Determined Contributions (NDC). To support this program through the PT ABC Sustainability Program, PT ABC's top management took the initiative to target a 35% reduction in greenhouse gas emissions (GHG emissions) by 2030 with a 2019 emissions baseline. The question for this paper is wants to know How the can writer identify the priority level of which machines should be streamlined or innovated and What machine process efficiency and innovation activities suit PT ABC's current condition. Conceptually, this research uses the DMAIC methodology as a framework. This methodology was chosen because this research will involve a lot of operational performance, which is likely more optimal if a breakdown analysis is carried out using the DMAIC methodology rules. In the Define phase, writer used Priority matrix analysis looks at 5 aspects: Electrical Energy Consumption, Gas Energy Consumption, CO2 consumption, Machine Quantity, and Operational Cost. Based on the highest score analysis matrix, the highest priority is the painting process. The painting process is considered to consume the highest electrical energy sources, produce the most CO2 emissions in the PT ABC production process, have the most number of machines operating in the PT ABC production process, and the most machine operating costs required in the PT ABC production process. . The Painting Process at PT ABC Plant Karawang consists of 11 lines consisting of the loading process, pretreatment process, coating process, oven process, and loading process.In the Measure Phase, writer record the energy consumption machine both in electrivity and LNG then calculate and conversion is made to CO2 emissions with tons units. Writer also using LCC analysis to know as is condition, it is necessary to conduct a more in-depth analysis related to the efficiency of operational costs on pretreatment machines, especially those that have an impact on reducing CO2 emissions, so that the optimization of pretreatment machine operational costs can be obtained and has an impact on the optimization of operational performance. In the Analysis phase, writer using pareto and fish bone diagram to know the main root causes. From that analysis, we know that methods, materials, and machines in the degreasing and phosphating processes in pretreatment must be improve to reduce CO2 emissions in the pretreatment process. In the improve phase, process improvement will be done on process painting line 1 as a pilot project. To carry out this improvement, some stages are carried out. The stages carried out by the ABC Team consist of several stages that are study stage, Laboratory Stages and Quality Check, Trial Line Proces Pretreatment Painting, Trial Line Proces Pretreatment Painting, Production Qualty Part Approval, Massproduction. With the improvement, the direct and direct impact is obtained with the following results. Decrease in energy consumption of process pretreatment plant karawang from the previous condition (the year 2019) to the after condition (the year 2023) of 134,860 kWh/month (17%) with pilot project process pretreatment line 1. Decrease in LNG consumption of pre-treatment process plant karawang from the previous condition (the year 2019) to the after condition (the year 2023) by 24,545 m3/month (27%) with pilot project process pre-treatment line 1. With electrical energy and LNG reduced, CO2 emissions are also reduced by 168 tons CO2/month (19%) with the pilot project process pre-treatment line 1. And contribute 4% from Target Company in Emission CO2 reduction. From the before and after data of LCC improvement above, this improvement has a good influence on the movement of LCC. This is very visible on the LCC trend graph in 2023. Before the improvement, an LCC value of Rp 166,957,034,894 will be obtained during the economic life of the machine for 8 years. However, after the improvement in the economic life of the machine, 8 years obtained an LCC of Rp 159,168,257,456. For the control phase, writer create system that can became framework can be a framework for PT ABC to carry out further activities related to reducing CO2 emissions generated by the machine. Moreover, the target given by the management of PT ABC is quite challenging, so the results of this research and the creation of this framework can help PT ABC achieve the targets that have been announced.