Design of working procedure for handling the breakdown machine in parameter of reaction time based on Jidoka system approach in cement company

Department of Industrial Engineering, Faculty of Engineering, Andalas University, 25163 Padang, Indonesia

^* Corresponding author: nilda@ft.unand.ac.id

Abstract

Packaging is not a complementary of the product. Packaging is an interface between producer and consumer in a supply chain. Portland cement is one of the products which is usually distributed in unit packed with bags made of kraft paper. Cement production that done with large capacity machines requires the amount of bag in quantity that much anyway. The production of bag factory in Cement company line 4 ideally could reach 9-10 million bags per month. In fact, the average production of cement bag from January to June 2012 is 6.5 million bags per month. In addition, the average defects of work in process in the range of the same month reached 56,000 tubes per month. This indicates that engine breakdown is happen frequently and there is a lack of good performance in term of production process quality control. Long reaction time of operator against the possible breakdown and the breakdown that occur is the cause of the length of time handling problems on the machine, so much going on a lot of waste in time and there are work in process defects that pass to the next process. Minimizing the reaction time to the breakdown of machine can be done with the implementation of jidoka system on the production floor. Andon which is the tool of jidoka will ensure operator and other parties (operators, technicians, foreman) gather to repair the machine effectively and also efficient in term of time. The lights that flashing and the sound of alarm that raised by andon will ensure this happen. Working procedures with the jidoka system approach is proven can minimize the reaction time to the breakdown of machine. Based on calculations, minimizing of time can reach up to 93.66%. The mathematical model for the jidoka system approach that has been valid then converted to a standard operating procedure in handling the breakdown of machine in bag factory. The standard operating procedure that proposed will be technically efficient and effective in terms of time and method to handle the breakdown of machine.