Reliability Improvement Process Case Study: PT HMS Tbk

https://doi.org/10.35912/jbpd.v3i2.4512
Published: Jan 20, 2024

Abstract:

Purpose: This study investigates the impact of unplanned and planned downtimes on PR (Production Reliability) performance in the tobacco industry, focusing on a company facing challenges due to COVID-19.

Method: A mixed-method approach is employed, combining quantitative data analysis of production lines (Q1 2024) with qualitative interviews. Root cause analysis (Current Reality Tree) and prioritization (Analytical Hierarchy Process) are used to identify and evaluate solutions.

Results: The research reveals maintenance focus on critical parts only and untested new materials as key contributors to low PR.

Conclusions: Improving Process Reliability at PT HMS requires a dual focus on minimizing unplanned disruptions through predictive maintenance and structured response strategies, while also optimizing planned maintenance to reduce its operational impact. Implementing a comprehensive maintenance framework and validating new materials through rigorous testing will ensure smoother production, fewer disruptions, and enhanced overall performance.

Limitations: The study focuses on one company during a specific timeframe.

Contributions: This research proposes a framework for improving PR by recommending a comprehensive maintenance plan, thorough material testing, and an implementation plan based on the PDCA cycle. This is expected to lead to enhanced PR, reduced downtimes, and improved operational efficiency.

Keywords:
1. Analytical Hierarchy Process
2. Current Reality Tree
3. Performance Improvement
Authors:
1 . Sylvania Putri
2 . Akbar Adhi Utama
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Putri, S. ., & Utama, A. A. . (2024). Reliability Improvement Process Case Study: PT HMS Tbk. Jurnal Bisnis Dan Pemasaran Digital, 3(2), 107–124. https://doi.org/10.35912/jbpd.v3i2.4512
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Issue & Section
Vol. 3 No. 2 (2024): Januari
Articles
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References

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    Awal, A., Mishra, A., Usman, G. M., & Abdul, A. (2018). Ontology Development for the Domain of Software Requirement Elicitation Technique. International Journal of Engineering Research & Technology (IJERT), 7(4), 334-338. doi:http://dx.doi.org/10.17577/IJERTV7IS040237

    Buer, S.-V., Semini, M., Strandhagen, J. O., & Sgarbossa, F. (2021). The Complementary Effect of Lean Manufacturing and Digitalisation on Operational Performance. International Journal of Production Research, 59(7), 1976-1992. doi:https://doi.org/10.1080/00207543.2020.1790684

    Cruz-Cardenas, J., Zabelina, E., Guadalupe-Lanas, J., Palacio-Fierro, A., & Ramos-Galarza, C. (2021). COVID-19, Consumer Behavior, Technology, and Society: A Literature Review and Bibliometric Analysis. Technological Forecasting and Social Change, 173, 1-13. doi:https://doi.org/10.1016/j.techfore.2021.121179

    Fiorello, M., Gladysz, B., Corti, D., Wybraniak-Kujawa, M., Ejsmont, K., & Sorlini, M. (2023). Towards a Smart Lean Green Production Paradigm to Improve Operational Performance. Journal of Cleaner Production, 413, 1-18. doi:https://doi.org/10.1016/j.jclepro.2023.137418

    Gunardi, Veranita, M., Agung, T., & Febyola, D. (2021). Pengaruh Kebijakan Pengenaan Tarif Cukai Rokok. Jurnal Co-Management, 4(2), 710-720. doi:https://doi.org/10.32670/comanagement.v4i2.1277

    Habib, M. A., Rizvan, R., & Ahmed, S. (2023). Implementing Lean Manufacturing for Improvement of Operational Performance in a Labeling and Packaging Plant: A Case Study in Bangladesh. Results in Engineering, 17, 1-14. doi:https://doi.org/10.1016/j.rineng.2022.100818

    Hajar, N., Supriyanto, & Syaifudin, A. (2021). Eksistensi Bisnis Tembakau di Masa Pandemi Covid-19 di UD Al-Musthofa. Jurnal Ilmiah Edunomika, 5(2), 726-730. doi:https://doi.org/10.29040/jie.v5i2.2446

    Harfianto, A., & Mukhlas, R. (2022). Dampak Krisis Global pada Industri Hasil Tembakau di Indonesia: Sebuah Analisis Runtun Waktu. Jurnal Pajak dan Keuangan Negara (PKN), 4(1S), 326-332. doi:https://doi.org/10.31092/jpkn.v4i1S.1918

    Imarah, T. S., & Jaelani, R. (2020). ABC Analysis, Forecasting and Economic Order Quantity (EOQ) Implementation to Improve Smooth Operation Process Dinasti International Journal of Education Management and Social Science, 1(3), 319-325. doi:https://doi.org/10.31933/dijemss.v1i3.149

    Irsan, Taba, M. I., & Hakim, H. (2022). Pengaruh Sistem Pemeliharan Total Productive Maintenance (TPM) dan Lean Manufacturing (LM) Terhadap Overall Equipment Effectiveness (OEE) (Studi Kasus di PT. Semen Tonasa). SEIKO: Journal of Management & Business, 5(1), 393-405. doi:https://doi.org/10.37531/sejaman.v5i1.2063

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    Pramann, S., Ajanakitti, K., Pohma, H., Wutichat, S., Tanphanich, T., & Pichainarongk, S. (2023). Factors Affecting Product Support to Promote Ideas and Improve Life through Movement Workshop Project. Paper presented at the Proceedings of the 8th ACPES (ASEAN Council of Physical Education and Sport) International Conference, Medan.

    Pratiwi, K. S. A. L., Karta, N. L. P. A., Ramanita, N. W. S., Aprilia, N. P. N., & Wardani, R. K. (2023). Penerapan Digital Marketing sebagai Media Pemasaran Global Guna Meningkatkan Penjualan Kain Tenun Gringsing Desa Tenganan Pegringsingan Bali. Jurnal Bisnis dan Pemasaran Digital, 2(2), 105-113. doi:https://doi.org/10.35912/jbpd.v2i2.2566

    Ramadhan, I., & Buani, D. C. P. (2023). Sistem Pendukung Keputusan Pemilihan Karyawan Terbaik Berdasarkan Kinerja dengan Metode Analytical Hierarchy Process (AHP). EVOLUSI: Jurnal Sains dan Manajemen, 11(1), 22-30. doi:https://doi.org/10.31294/evolusi.v11i1.14966

    Rizka, A., Asbari, M., & Setiawan, R. A. (2024). Penerapan Prinsip Lean Manufacturing untuk Efisiensi Operasional dan Produktivitas: Tinjauan Literatur. Jurnal Ilmu Sosial, Manajemen, Akuntansi dan Bisnis, 1(2), 42-46. doi:https://doi.org/10.70508/z3c9yp63

    Saaty, T. L. (1980). The Analytic Hierarchy Process. New York: McGraw-Hill.

    Solihat, S. S. (2023). Urgensi Kebijakan Kenaikan Tarif Cukai Rokok Elektrik di Indonesia. Owner: Riset dan Jurnal Akuntansi, 7(3), 2389-2400. doi:https://doi.org/10.33395/owner.v7i3.1480

    Sreenivasan, A., Suresh, M., & Nedungadi, P. (2023). Mapping Analytical Hierarchy Process Research to Sustainable Development Goals: Bibliometric and Social Network Analysis. Heliyon, 9(8), 1-23. doi:https://doi.org/10.1016/j.heliyon.2023.e19077

    Tonon, G. (2015). Integration of Qualitative and Quantitative Methods in Quality of Life Studies. Qualitative Studies in Quality of Life: Methodology and Practice, 55, 53-60. doi:https://doi.org/10.1007/978-3-319-13779-7_4

    Wardhani, A. K., & Romas, A. N. (2021). Analisis Strategi Digital Marketing Di Masa Pandemi Covid-19. EXERO: Journal of Research in Business and Economics, 4(1), 29-54. doi:https://doi.org/10.24071/exero.v4i1.5025

    Williams, C. (2007). Research Methods. Journal of Business & Economic Research, 5(3). doi:https://doi.org/10.19030/jber.v5i3.2532

    Womack, J. P., Jones, D. T., & Roos, D. (2007). The Machine That Changed the World: The Story of Lean Production, Toyota’s Secret Weapon in the Global Car Wars That Is Now Revolutionizing World Industry. New York: Free Press.

    Yingst, J. M., Krebs, N. M., Bordner, C. R., Hobkirk, A. L., Allen, S. I., & Foulds, J. (2021). Tobacco Use Changes and Perceived Health Risks Among Current Tobacco Users During the COVID-19 Pandemic. International Journal of Environmental Research and Public Health, 18(4), 1-10. doi:https://doi.org/10.3390/ijerph18041795

  1. Amansyah, M., Putri, R. A., Akila, N., & Amelia, F. (2023). Menggali Masalah yang Terjadi dengan Focus Group Discussion (FGD) di Dusun Halahalaya, Kabupaten Gowa. Sociality: Journal of Public Health Service, 2(2), 166-172. doi:https://doi.org/10.24252/sociality.v2i2.40316
  2. Asnan, R., Nordin, N., & Othman, S. N. (2015). Managing Change on Lean Implementation in Service Sector. Procedia - Social and Behavioral Sciences, 211, 313-319. doi:https://doi.org/10.1016/j.sbspro.2015.11.040
  3. Awal, A., Mishra, A., Usman, G. M., & Abdul, A. (2018). Ontology Development for the Domain of Software Requirement Elicitation Technique. International Journal of Engineering Research & Technology (IJERT), 7(4), 334-338. doi:http://dx.doi.org/10.17577/IJERTV7IS040237
  4. Buer, S.-V., Semini, M., Strandhagen, J. O., & Sgarbossa, F. (2021). The Complementary Effect of Lean Manufacturing and Digitalisation on Operational Performance. International Journal of Production Research, 59(7), 1976-1992. doi:https://doi.org/10.1080/00207543.2020.1790684
  5. Cruz-Cardenas, J., Zabelina, E., Guadalupe-Lanas, J., Palacio-Fierro, A., & Ramos-Galarza, C. (2021). COVID-19, Consumer Behavior, Technology, and Society: A Literature Review and Bibliometric Analysis. Technological Forecasting and Social Change, 173, 1-13. doi:https://doi.org/10.1016/j.techfore.2021.121179
  6. Fiorello, M., Gladysz, B., Corti, D., Wybraniak-Kujawa, M., Ejsmont, K., & Sorlini, M. (2023). Towards a Smart Lean Green Production Paradigm to Improve Operational Performance. Journal of Cleaner Production, 413, 1-18. doi:https://doi.org/10.1016/j.jclepro.2023.137418
  7. Gunardi, Veranita, M., Agung, T., & Febyola, D. (2021). Pengaruh Kebijakan Pengenaan Tarif Cukai Rokok. Jurnal Co-Management, 4(2), 710-720. doi:https://doi.org/10.32670/comanagement.v4i2.1277
  8. Habib, M. A., Rizvan, R., & Ahmed, S. (2023). Implementing Lean Manufacturing for Improvement of Operational Performance in a Labeling and Packaging Plant: A Case Study in Bangladesh. Results in Engineering, 17, 1-14. doi:https://doi.org/10.1016/j.rineng.2022.100818
  9. Hajar, N., Supriyanto, & Syaifudin, A. (2021). Eksistensi Bisnis Tembakau di Masa Pandemi Covid-19 di UD Al-Musthofa. Jurnal Ilmiah Edunomika, 5(2), 726-730. doi:https://doi.org/10.29040/jie.v5i2.2446
  10. Harfianto, A., & Mukhlas, R. (2022). Dampak Krisis Global pada Industri Hasil Tembakau di Indonesia: Sebuah Analisis Runtun Waktu. Jurnal Pajak dan Keuangan Negara (PKN), 4(1S), 326-332. doi:https://doi.org/10.31092/jpkn.v4i1S.1918
  11. Imarah, T. S., & Jaelani, R. (2020). ABC Analysis, Forecasting and Economic Order Quantity (EOQ) Implementation to Improve Smooth Operation Process Dinasti International Journal of Education Management and Social Science, 1(3), 319-325. doi:https://doi.org/10.31933/dijemss.v1i3.149
  12. Irsan, Taba, M. I., & Hakim, H. (2022). Pengaruh Sistem Pemeliharan Total Productive Maintenance (TPM) dan Lean Manufacturing (LM) Terhadap Overall Equipment Effectiveness (OEE) (Studi Kasus di PT. Semen Tonasa). SEIKO: Journal of Management & Business, 5(1), 393-405. doi:https://doi.org/10.37531/sejaman.v5i1.2063
  13. Moyano-Fuentes, J., Maqueira-Marín, J. M., Martínez-Jurado, P. J., & Sacristan-Diaz, M. (2021). Extending Lean Management Along the Supply Chain: Impact on Efficiency. Journal of Manufacturing Technology Management, 32(1), 63-84. doi:https://doi.org/10.1108/JMTM-10-2019-0388
  14. Pramann, S., Ajanakitti, K., Pohma, H., Wutichat, S., Tanphanich, T., & Pichainarongk, S. (2023). Factors Affecting Product Support to Promote Ideas and Improve Life through Movement Workshop Project. Paper presented at the Proceedings of the 8th ACPES (ASEAN Council of Physical Education and Sport) International Conference, Medan.
  15. Pratiwi, K. S. A. L., Karta, N. L. P. A., Ramanita, N. W. S., Aprilia, N. P. N., & Wardani, R. K. (2023). Penerapan Digital Marketing sebagai Media Pemasaran Global Guna Meningkatkan Penjualan Kain Tenun Gringsing Desa Tenganan Pegringsingan Bali. Jurnal Bisnis dan Pemasaran Digital, 2(2), 105-113. doi:https://doi.org/10.35912/jbpd.v2i2.2566
  16. Ramadhan, I., & Buani, D. C. P. (2023). Sistem Pendukung Keputusan Pemilihan Karyawan Terbaik Berdasarkan Kinerja dengan Metode Analytical Hierarchy Process (AHP). EVOLUSI: Jurnal Sains dan Manajemen, 11(1), 22-30. doi:https://doi.org/10.31294/evolusi.v11i1.14966
  17. Rizka, A., Asbari, M., & Setiawan, R. A. (2024). Penerapan Prinsip Lean Manufacturing untuk Efisiensi Operasional dan Produktivitas: Tinjauan Literatur. Jurnal Ilmu Sosial, Manajemen, Akuntansi dan Bisnis, 1(2), 42-46. doi:https://doi.org/10.70508/z3c9yp63
  18. Saaty, T. L. (1980). The Analytic Hierarchy Process. New York: McGraw-Hill.
  19. Solihat, S. S. (2023). Urgensi Kebijakan Kenaikan Tarif Cukai Rokok Elektrik di Indonesia. Owner: Riset dan Jurnal Akuntansi, 7(3), 2389-2400. doi:https://doi.org/10.33395/owner.v7i3.1480
  20. Sreenivasan, A., Suresh, M., & Nedungadi, P. (2023). Mapping Analytical Hierarchy Process Research to Sustainable Development Goals: Bibliometric and Social Network Analysis. Heliyon, 9(8), 1-23. doi:https://doi.org/10.1016/j.heliyon.2023.e19077
  21. Tonon, G. (2015). Integration of Qualitative and Quantitative Methods in Quality of Life Studies. Qualitative Studies in Quality of Life: Methodology and Practice, 55, 53-60. doi:https://doi.org/10.1007/978-3-319-13779-7_4
  22. Wardhani, A. K., & Romas, A. N. (2021). Analisis Strategi Digital Marketing Di Masa Pandemi Covid-19. EXERO: Journal of Research in Business and Economics, 4(1), 29-54. doi:https://doi.org/10.24071/exero.v4i1.5025
  23. Williams, C. (2007). Research Methods. Journal of Business & Economic Research, 5(3). doi:https://doi.org/10.19030/jber.v5i3.2532
  24. Womack, J. P., Jones, D. T., & Roos, D. (2007). The Machine That Changed the World: The Story of Lean Production, Toyota’s Secret Weapon in the Global Car Wars That Is Now Revolutionizing World Industry. New York: Free Press.
  25. Yingst, J. M., Krebs, N. M., Bordner, C. R., Hobkirk, A. L., Allen, S. I., & Foulds, J. (2021). Tobacco Use Changes and Perceived Health Risks Among Current Tobacco Users During the COVID-19 Pandemic. International Journal of Environmental Research and Public Health, 18(4), 1-10. doi:https://doi.org/10.3390/ijerph18041795