Mengurangi Cost Preventif Maintenance Dengan Reduce Push Button Confirmation JIG

Abstract

Preventive Maintenance (PM) plays a crucial role in maintaining machine performance and ensuring smooth production processes in manufacturing environments. However, PM implementation often incurs considerable costs, especially when certain components experience recurrent failures. This study was conducted on the Confirmation JIG machine in the Helium Line at PT XYZ, which showed an increase in PM costs due to routine damage to the control box and push button components. These components suffered physical damage such as dents and breakage because their installation followed the movement of each JIG on the rotary table, making them prone to collisions during the dandori process. This condition led to cost waste and had the potential to disrupt production continuity.

The objective of this study was to provide a systematic solution to reduce PM costs through a Kaizen approach and the application of the Plan–Do–Check–Action (PDCA) cycle. Root cause identification was carried out using a 5Why+1H analysis to thoroughly investigate the causes of damage until the main source of the problem was identified. Based on the analysis results, it was found that the design and positioning of the control box and push button were critical factors contributing to the high risk of damage.

Therefore, improvement measures were implemented in the form of designing a common control box placed at a single fixed position, mechanical modifications through the fabrication of a support arm for the push button, and adjustments to the PLC program to ensure optimal operational functionality despite changes in the control system layout. The implementation stage included designing the arm using Autodesk Inventor, mechanical installation, wiring installation, and PLC reprogramming.

After functional testing during the Check phase, the new system demonstrated more stable performance and eliminated the collision risks present in the previous condition. The final results of the study showed a very significant reduction in Preventive Maintenance costs, from IDR 19,812,792 to IDR 1,651,066, representing a reduction of approximately 92% of the previous total cost. In addition, these improvements enhanced operator safety, extended component service life, and reduced the potential for chokotei that could disrupt production flow.

Overall, this study proves that the implementation of Kaizen based on the PDCA cycle can deliver tangible impacts in improving cost efficiency and machine reliability. This strategy can serve as a reference for other manufacturing companies seeking to reduce waste, improve maintenance quality, and continuously optimize production processes.

Keywords: Preventive Maintenance, Kaizen, PDCA.