ANALISIS PENERAPAN OTOMATISASI PENIMBANGAN AIR DAN MINYAK TERHADAP EFISIENSI TENAGA KERJA MELALUI PENDEKATAN PDCA DAN RCA

Abstract

Abstract: This study aims to analyze the implementation of an automated water and oil weighing system in relation to labor efficiency through the Plan Do Check Act (PDCA) and Root Cause Analysis (RCA) approaches in the chilled water and RBD Palm Olein weighing process at PT MYZ Plant Jayanti 1. The research problem originated from a weighing process that was still performed manually, resulting in repetitive work activities, relatively long processing time, and high operator involvement. This study employed a quantitative descriptive method with a case study approach. Data were collected through observation, interviews, documentation, and work-time measurements. RCA was used to identify the root causes of problems based on the Man, Method, and Machine factors, while PDCA was used as a framework for implementing improvement actions through the application of an automated weighing system. The results showed that the initial weighing process required 8.126 minutes per batch, while after automation it decreased to 4.39 minutes per batch, representing a reduction of 3.736 minutes per batch or approximately 46%. Labor requirements changed from 3 operators to 2 operators per shift, representing a reduction of 1 operator or 33.33%. The core weighing activities also decreased from four to three activity elements. Based on the RCA, five root causes were identified with a total frequency of 551 occurrences per shift, consisting of factors related to Method, Man, and Machine. During the evaluation after automation, no weighing discrepancy was found for the materials observed. However, the processing-time target of 3.54 minutes per batch was not fully achieved, as the actual result remained at 4.39 minutes per batch. Therefore, the implementation of automation supported by RCA and PDCA demonstrated changes in processing time, manual activities, and labor requirements based on a comparison of process conditions before and after the implementation of the automated weighing system.

Keywords: automation, water and oil weighing, labor efficiency, PDCA, RCA.

Abstrak: Penelitian ini bertujuan untuk menganalisis penerapan sistem otomatisasi penimbangan air dan minyak terhadap efisiensi tenaga kerja melalui pendekatan Plan Do Check Act (PDCA) dan Root Cause Analysis (RCA) pada proses penimbangan air chiller dan minyak RBD Palm Olein di PT MYZ Plant Jayanti 1. Permasalahan penelitian berawal dari proses penimbangan yang masih dilakukan secara manual sehingga menimbulkan aktivitas kerja berulang, waktu proses yang relatif tinggi, serta ketergantungan terhadap keterlibatan operator. Penelitian ini menggunakan metode deskriptif kuantitatif dengan pendekatan studi kasus. Data diperoleh melalui observasi, wawancara, dokumentasi, dan pengukuran waktu kerja. RCA digunakan untuk mengidentifikasi akar penyebab permasalahan berdasarkan faktor Man, Method, dan Machine, sedangkan PDCA digunakan sebagai kerangka pelaksanaan tindakan perbaikan melalui penerapan sistem otomatisasi. Hasil penelitian menunjukkan bahwa kondisi awal proses penimbangan membutuhkan waktu 8,126 menit/batch, sedangkan setelah penerapan otomatisasi menjadi 4,39 menit/batch, sehingga terjadi penurunan waktu proses sebesar 3,736 menit/batch atau sekitar 46%. Kebutuhan tenaga kerja berubah dari 3 orang menjadi 2 orang per shift, atau berkurang sebanyak 1 orang dengan persentase perubahan sebesar 33,33%. Aktivitas inti proses penimbangan juga berkurang dari empat menjadi tiga elemen aktivitas. Berdasarkan RCA, teridentifikasi lima akar penyebab dengan total frekuensi kejadian sebesar 551 kejadian/shift, yang terdiri atas faktor Method, Man, dan Machine. Pada tahap evaluasi setelah otomatisasi, tidak ditemukan selisih hasil penimbangan pada material yang diamati. Namun, target waktu proses sebesar 3,54 menit/batch belum sepenuhnya tercapai karena hasil aktual masih sebesar 4,39 menit/batch. Dengan demikian, penerapan otomatisasi yang didukung RCA dan PDCA menunjukkan adanya perubahan pada waktu proses, aktivitas manual, dan kebutuhan tenaga kerja berdasarkan perbandingan kondisi sebelum dan sesudah penerapan sistem otomatisasi.

Kata Kunci: otomatisasi, penimbangan air dan minyak, efisiensi tenaga kerja, PDCA, RCA.