DEVELOPING DMAIC MAINTENANCE TO INCREASE MACHINE PERFORMANCE IN PT. XYZ AND GAINING BUSINESS SUSTAINABILITY IN PT. UNITED TRACTORS

Abstract

PT. XYZ is an Indonesian coal hauling contractor works with Scania double trailer R580 and R620. Physical availability decline from R580 to 75% and R620 to 81% in the first semester of 2022 hindered PT. XYZ to gain revenue. The main concern was to achieve physical availability target of 83% (R580) and 85% (R620). By doing intense FGD, UT conceived customer voice (VOC) and gathered all correlated parameters to focus on utmost priority parameters using Kano Model – QFD approach. Six Sigma DMAIC methodology identified defects and executed RPN based improvement. Using process capability analysis, R580 physical availability increased to 86% (July 2023), with the increment of Cpk from 0.61 to 1.22, Cp from 0.62 to 1.33, Ppk from 0.64 to 0.94, and Pp from 0.63 to 0.86. While R620 physical availability increased to 88% (July 2023), with the decrement of Cpk from 0.61 to 0.14, Cp from 0.62 to 0.67, Ppk from 0.55 to 0.10, Pp from 0.56 to 0.52. Physical availability significantly correlated with selected parameters: MTTR, PI achievement, backlog execution rate, component and system mandatory, OTIF mechanic and VHS availability. The stability of the process was maintained using control charts to warn special causes that disturbed the system.