IMPLEMENTATION OF PDCA CYCLE TO IMPROVE THE RELIABILITY OF WOODPECKER COMPONENTS ON 55 TON PRESS MACHINE AT PT CIPTAUNGGUL KARYA ABADI

Abstract

This study aims to improve the reliability of trigger components in a 55-ton press machine at PT. Ciptaunggul Karya Abadi through the implementation of the Plan-Do-Check-Act (PDCA) cycle which is integrated with the Root Cause Analysis (RCA), Fault Tree Analysis (FTA), and Failure Mode and Effect Analysis (FMEA) methods. The main problem faced by the company is the high level of downtime due to repeated damage to the trigger components, which has an impact on decreased production efficiency and increased maintenance costs. This study uses a descriptive case study design with a combination of qualitative and quantitative approaches. Data was collected through field observations, interviews with technicians and operators, and analysis of historical documents related to the frequency of breakdowns and downtime. RCA and FTA analysis were used to identify the root cause of damage, while the FMEA method was applied to assess the level of risk through the calculation of the Risk Priority Number (RPN). The results showed that the main cause of damage was the life of materials that were not systematically monitored with the highest RPN value of 20.6, which was categorized as a "tolerable" risk but still required preventive measures. The implementation of the PDCA cycle results in a preventive maintenance system based on actual lifespan with the stages of replacement planning, testing of new procedures, evaluation of results, and determination of preventive replacement procedures as operational standards. The 5W1H approach is also used to formulate repair strategies through periodic inspections, recording component life, and setting replacement thresholds. The results of the implementation show the potential for a significant reduction in downtime and improved engine maintenance efficiency.