DASAR PERHITUNGAN KAPASITAS TERPASANG PLASTIC INJECTION

PLANT 4 CIKAMPEK
Working Time SHIFT 1 SHIFT 2 SHIFT 3 TOTAL
Available working time 07.00-16.00 540 16.00-24.00 480 00.00-07.00 420 1440
Planned shut down No Intention of running production
Non Working Time SHIFT 1 SHIFT 2 SHIFT 3 Min %
1 P5M Instruction 07.00-07.05 5 16.00-16.05 0 00.00-00.05 0
2 Total Productive Maintenance Pengecekan dan 07.05-07.15 5 - 5 - 0
Pengecekan utility dan
3 Cleaning/Checking pembersihan area kerja 07.15-07.20 5 16.05-16.10 5 00.05-00.10 5

4 Break 1 09.30-09.40 10 18.00-18.10 10 - 0

5 Break 2 12.00-12.40 40 19.20-20.00 40 03.00-04.00 60
6 Break 3 14.20-14.30 10 22.00-22.10 10 - 0
TOTAL Planned Shut Down 75 70 65
Planned Production Time
Remaining available time
465 410 355 1230 100%
Effective Working Time SHIFT 1 SHIFT 2 SHIFT 3 Min %
Downtime Mesin Terjadi kerusakan pada
mesin 0.6% 3.0 0.7% 3.0 0.8% 3.0 9.0 0.73%
Breakdown Mesin, setting, Trial
Downtime Mold
0.4% 2.1 0.5% 2.1 0.6% 2.1 6.15 0.50%
Ganti Mold, Breakdown Mold
Downtime Material
0.4% 1.6 0.4% 1.6 0.5% 1.6 4.92 0.40%
Reject material ( ABS 0,85 %, PP 0,7 % )
Downtime Support
0.4% 1.6 0.4% 1.6 0.5% 1.6 4.92 0.40%
Breakdown
Performance Loss
0.9% 4.1 1.0% 4.1 1.2% 4.1 12.3 1.00%
Reduce speed
Quality Loss
0.2% 0.8 0.2% 0.8 0.2% 0.8 2.46 0.20%
Reject part
TOTAL 2.8% 13.3 3.2% 13.3 3.7% 13.3 39.75 3.23%

Effective Working Time EWT [ % I minute ] 452 397 342 1191 96.8%
451.8 396.8 341.8
Investme
nt
ITEMS B/M Tujuan Act. Target Target 　 Theme
Act New

Ｑ NG in Processing 0.34% 0.2% 0.3% 0.2% -0.02% Improve proses feeding, proses ganti material ー ●

Ｃ Cycle Time 42.0se 42.0se 57.0se cycle M/C 　 Aplikasi Robot & Cutting
45.0sec -12.0 秒 High ー ●
c c c Gate

42.0sec -15.0 秒 Aplikasi Mold Multi Family － ●

Ｃ Material Efficiency 99.5% 99.5% 93.7% 99.6% +5.9 秒 High cycle M/C 　 Aplikasi Robot & Cutting
Gate ー ●

Ｃ Pengurangan Man Power ー ー 90org 42org -48org Central (Cluster) Part Finishing － ●

Ｄ Mold Change 18.0se 15.0se Improve Mold Cooling Design dan

20sec 15sec -5.0sec Perubahan metode Mold Change － ●
c c
HVN HVN AHJ AHJ
BM (2012 (PLAN (2012 (NewPla
) T 3) ) nt)
NG in Process 0,34 0,22
% 0,4% 0,28% % 0,2%
( 工程内不良 )
Reject after Process 0,27 0,01
0,4% 0,18% 0,01%
( 次区流出不良 ) % %
Reject lolos Check
0,3% 0,3% 0,28% 0,0% 0,0%
( 完検 不良
検検 )
Cycle Time (s)
42 50,9 42 57 45
( 成形サイクル )
Material Efficiency 99,5 99,5 93,7
% % 99,6% % 99,6%
( 材料使用効率 )
MC Effectiveness
96% 96% 96,6% 96,51 96,8%
( 稼働率 ) %
Mold Change (mnt)
18 25 18 20 15
( 金型交換時間 )
Lead time (day)
1 1,3 1 0,9 0,7
( 製造リードタイム )
Data Downtime 2013 1 2 3 4 5 6 7 8 9 10 11
800 670 1315 1219 760 505 1695 650 414 1095 625
Avg DTM
Unit Mesin
Hari Kerja Efektif
DTM Harian
 12 Total
555 10303
Avg DTM 858.58 Downtime mesin
Unit Mesin 21 Harian 10 220
Hari Kerja Efektif 25
DTM Harian 1.635397 menit Breakd 400
HK 22 hari
unit mesin 14 Unit mesin
beban 1 ha1.298701 menit

Setting 5
Frekuen 1
HK (minggu 6
beban 1 ha0.833333 menit

Trial
Target
Tujua
ITEMS B/M Act. Target Target 　 Theme
n
Improve proses feeding, proses ganti
Ｑ NG in Processing 0.34% 0.2% 0.3% 0.2% -0.02% material

Ｃ Cycle Time 42.0se 42.0se 57.0se -12.0 High cycle M/C 　 Aplikasi Robot & Cutt
45.0sec
c c c 秒 Gate
-15.0
42.0sec Aplikasi Mold Multi Family
秒
Ｃ Material Efficiency +5.9 High cycle M/C 　 Aplikasi Robot & Cutt
99.5% 99.5% 93.7% 99.6%
秒 Gate

Ｃ Pengurangan Man Power ー ー 90org 42org -48org Central (Cluster) Part Finishing

Ｄ Mold Change 18.0se 15.0se - Improve Mold Cooling Design dan

20sec 15sec
c c 5.0sec Perubahan metode Mold Change
HVN
BM (201
2)
NG in Process 0,34 0,4%
( 工程内不良 ) %
Reject after
0,27
Process 0,4% %
( 次区流出不良 )
Reject lolos Check
0,3% 0,3%
( 完検 不良
検検 )
Cycle Time (s)
42 50,9
( 成形サイクル )
Material
99,5 99,5
Efficiency % %
( 材料使用効率 )
MC Effectiveness
96% 96%
( 稼働率 )
Mold Change (mnt)
18 25
( 金型交換時間 )
Lead time (day)
( 製造リードタイ 1 1,3
ム)
 Investme
nt
　 Theme Ne
Act
w
prove proses feeding, proses ganti
terial ー ●
h cycle M/C 　 Aplikasi Robot & Cutting
e ー ●

likasi Mold Multi Family － ●

h cycle M/C 　 Aplikasi Robot & Cutting
e ー ●

ntral (Cluster) Part Finishing － ●

prove Mold Cooling Design dan

rubahan metode Mold Change － ●

HVN HVN AHJ AHJ

(201 (PLAN (201 (NewPl
2) T 3) 2) ant)
0,22
0,4% 0,28% 0,2%
%
0,27 0,01
0,18% 0,01%
% %

0,3% 0,28% 0,0% 0,0%

50,9 42 57 45

99,5 93,7
99,6% 99,6%
% %
96,5
96% 96,6% 96,8%
1%

25 18 20 15

1,3 1 0,9 0,7