ANALISIS RISIKO KUALITAS PRODUK PADA PROSES PRODUKSI SEMEN DI PT SEMEN GRESIK PABRIK TUBAN I

Abstract

In an effort to produce quality products, PT Semen Gresik Pabrik Tuban I often face various risks in the form of damage or disruption during production process. Therefore, needed the supervision and controlling during production process to minimize probability of quality risk occurrence. In this research, FMEA is used to identify quality risks in cement production process and to assess the level of risk probability (occurrence) and risk impact (severity). FMEA results indicate that there are 19 quality risks in cement production process. Through probability-impact matrix, can be seen that there are some critical quality risks and must be mitigated. Critical risks include, the risk of wet material, flushing, disruption of material transportation and size of material that too big (out of material specification). Monte Carlo simulation are used to evaluate critical risks that influenced by internal factors and controllable factors. The risk is disruption of material transportation that caused by machine failure due to lack of machine maintenance. In this case, the simulations are performed to determine mean time between failure and mean time to repair, so can be decided when the optimal preventive maintenance can be performed. The simulation results show that the mean time between failure is 115.1636 hours and mean time to repair is 1.1624 hours. Thus, mitigation effort that can be done is through preventive maintenance before that mean time between failure. Other mitigations of critical risks include maintenance of machine cleanliness, routine inspection during production process, increasing the number of operators, FMEA documentation, and communication and coordination improvement.