Update Artikelilmiah: 49092

BAGJA HANIFAN HILMANA

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Abstrak (Bhs. Indonesia)

Penelitian ini dilatarbelakangi oleh tingginya downtime dan keterbatasan kinerja mesin EPS Shape Molding (1996) yang masih mengandalkan sistem kontrol konvensional electromechanical. Permasalahan utama meliputi kesulitan pengaturan parameter produksi, ketersediaan suku cadang, serta inkonsistensi kualitas polyfoam. Tujuan penelitian ialah merancang dan mengimplementasikan sistem kontrol digital berbasis PLC Omron NX1P2 dan HMI Weintek MT8102iP untuk meningkatkan efisiensi, keandalan, dan kualitas produksi. Metode yang digunakan mencakup perancangan ulang electrical wiring diagram, pemrograman ladder logic di Sysmac Studio, dan pembuatan antarmuka operator menggunakan EasyBuilder Pro. Implementasi meliputi penggantian hardware lama, rewiring, instalasi PLC-HMI, serta pengujian konektivitas, fungsi operasi manual, dan mode operasi otomatis. Evaluasi performa menggunakan analisis rekam data produksi pra dan pasca retrofit dengan standar Overall Equipment Effectiveness (OEE). Hasil menunjukkan peningkatan laju produksi dari 0,644 menjadi 0,694 produk baik per menit, penurunan total waktu breakdown dari 660 menjadi 555 menit dalam tiga bulan, serta kenaikan OEE hingga mendekati 100 % (Quality > 99 %, Availability hingga 99,81 %, Performance > 100 %). Produktivitas operator bertambah dari rata-rata 38 unit/jam menjadi 42,75 unit/jam. Kesimpulannya, penerapan sistem kontrol digital signifikan memperbaiki efisiensi operasional, stabilitas proses, dan konsistensi kualitas polyfoam, sekaligus memperpanjang usia pakai mesin tanpa modifikasi struktural besar.

Abtrak (Bhs. Inggris)

This study was motivated by the high downtime and limited Performance of the EPS Shape Molding machine (1996), which still relies on a conventional electromechanical control system. The main problems include difficulties in setting production parameters, Availability of spare parts, and inconsistency in the quality of polyfoam. The objective of this study is to design and implement a digital control system based on Omron NX1P2 PLC and Weintek MT8102iP HMI to improve production efficiency, reliability, and quality. The methods used include redesigning the electrical wiring diagram, programming ladder logic in Sysmac Studio, and creating an operator interface using EasyBuilder Pro. The implementation involved replacing old hardware, rewiring, installing the PLC-HMI, and testing connectivity, as well as manual and automatic operation modes. Performance evaluation was conducted using production data analysis before and after the retrofit, with the Overall Equipment Effectiveness (OEE) standard as a benchmark. Results showed an increase in production rate from 0.644 to 0.694 good products per minute, a reduction in total breakdown time from 660 to 555 minutes over three months, and an increase in OEE to nearly 100% (Quality > 99%, Availability up to 99.81%, Performance > 100%). Operator productivity increased from an average of 38 units per hour to 42.75 units per hour. In conclusion, the implementation of the digital control system has significantly improved operational efficiency, process stability, and quality consistency of polyfoam while extending the machine's service life without requiring major structural modifications.

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