Analisis Produktivitas pada Mesin Koenig & Bauer Sheetfed sebagai Dasar Usulan Reliability Centered Maintenance (RCM) di PT. XYZ

Muhamad Farhan Rizki Pratama; Hilyatun Nuha

doi:10.58192/populer.v5i2.4524

Authors

Muhamad Farhan Rizki Pratama Universitas 17 Agustus 1945 Surabaya
Hilyatun Nuha Universitas 17 Agustus 1945 Surabaya

DOI:

https://doi.org/10.58192/populer.v5i2.4524

Keywords:

Fishbone Diagram, Objective Matrix, Productivity, Reliability Centered Maintenance, Statistical Quality Control

Abstract

Production machine productivity is an important factor in supporting the effectiveness and efficiency of manufacturing production systems. PT XYZ experienced unstable productivity, high downtime, production losses, and product defects on the Koenig & Bauer Sheetfed (KBA) machine, which affected production performance and maintenance costs. Therefore, productivity analysis and a structured preventive maintenance system were required to improve machine reliability.This study aims to measure machine productivity using the Objective Matrix (OMAX) method, identify the causes of low productivity through Statistical Quality Control (SQC), Fishbone Diagram, and Failure Mode and Effect Analysis (FMEA), and determine preventive maintenance recommendations using Reliability Centered Maintenance (RCM). The research data included production output, downtime, operating time, labor, energy consumption, and component failure data from July–December 2025.The results showed that the productivity index fluctuated during the observation period, with the highest productivity index reaching 31.89% in October 2025. The dominant causes of low productivity originated from machine conditions, work methods, and production quality. Based on FMEA and RCM analysis, the critical components identified were brush feeding, roller printing, and register wire rope. Preventive maintenance intervals were determined using Weibull distribution, Mean Time To Failure (MTTF), and Mean Time To Repair (MTTR) analysis. The implementation of RCM-based preventive maintenance reduced maintenance costs by 74.98%, from IDR 79,750,000 to IDR 19,950,000, while also reducing downtime and improving the operational stability of the KBA machine at PT XYZ.

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