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MMP is a metal manufacturing company engaged in casting, forging, and machining processes with a three-shift work system, including night shifts that may increase mental and physical workload due to disruptions in workers’ biological rhythms. This study aims to analyze the mental and physical workload of die casting machine operators during the night shift and to propose improvement measures using the Fault Tree Analysis (FTA) method. The study involved 23 operators, with mental workload assessed using NASA-TLX and physical workload measured using CVL. The results indicate that mental workload falls into high to very high categories, with WWL values ranging from 46.6 to 97.3, where 12 operators experienced very high mental workload. The dominant contributing dimensions were effort, physical demand, and temporal demand. Meanwhile, physical workload ranged from 19.48% to 36.36% CVL, with most operators not experiencing fatigue. Although physical workload remains within acceptable limits, the high mental workload indicates the need for improvements. FTA analysis identified key contributing factors, including work methods, work systems, ergonomics, machine conditions, and the work environment. Proposed improvements include job rotation, improvements in work methods and task distribution, adjustments to the work system, enhanced machine maintenance, and ergonomics-based workplace improvements.

The rapid advancement of information technology has encouraged business actors to adopt digital transformation; this situation is also experienced by Pabrik Tahu Macanan, a small scale tofu factory in Magelang that still relies on manual systems in operation. This  study aims to analyze the implementation of management information systems in supporting digital transformation and risk management at Pabrik Tahu Macanan; a descriptive qualitative approach was applied, using interviews, observations, and documentation as date collection methods. The findings reveal that digital information systems have the potential to improve efficiency, recording accuracy, and internal control; however, their implementation remains limited due to human resource constraints and low adaptability to new technologies. The research also found that simple risk management practices such as regular machine maintenance and manual bookkeeping remain effective in maintaining business stability. The implication of this study indicates that a gradual implementation of digital based information systems, supported by training and supervision, can serve as a strategic step to enhance competitiveness, operational efficiency, and sustainability for traditional SMEs like Pabrik Tahu Macanan.

PT. YGI, an automotive manufacturing company, uses the Press Injection GB-36 machine in its production process. However, this machine frequently experiences failures, causing high downtime and reduced production efficiency. This study aims to identify the types of failures, determine the most critical components, and propose a maintenance system using the Reliability Centered Maintenance (RCM) approach. The method used is descriptive qualitative, involving FMEA (Failure Mode and Effect Analysis), Logic Tree Analysis (LTA), and maintenance action selection. Data were collected through observations, historical failure documentation, and interviews. The analysis results indicate that components such as the injection nozzle, heating, and clamping are the most critical, contributing over 80% of total failures based on Pareto analysis and the highest RPN values in FMEA. Proposed maintenance actions include Condition Directed and Time Directed approaches. Additionally, the maintenance system is supplemented with standard operating procedures (SOP) and routine inspection schedules to improve machine reliability and reduce production downtime. This study is expected to enhance the efficiency and productivity of the Press Injection GB-36 machine at PT. YGI through the appropriate implementation of RCM.

PT Sinar Semesta is a company engaged in the metal casting industry. In its production process, defects were still found during the period from March 2023 to February 2024. Out of a total production of 4,950 units, there were 1,004 defective units, consisting of 534 units with flow error defects and 470 units with porosity defects. To address this issue, quality control methods such as Statistical Quality Control (SQC) and Fault Tree Analysis (FTA) are necessary to minimize product defects, improve quality, and maintain high standards. Based on the Pareto diagram, the most dominant defect percentages are flow error defects at 53.19% and porosity defects at 46.81%. The control chart shows points beyond the upper control limit (UCL) occurring in April with 148 units, May with 145 units, and October with 149 units, and below the lower control limit (LCL) occurring in August with 35 units, January with 36 units, and February with 32 units. Based on the fault tree analysis, five main factors causing defects were identified: human, machine, raw material, method, and environment. Proposed improvements include operator training, routine machine maintenance, accurate raw material measurement, use of high-quality raw materials, pre-pouring temperature checks, increased supervision, and environmental improvements.

This The maintenance objectives of a C6240A-type lathe involve a number of crucial aspects, including gears, tool bits, toolposts, lower sled and upper sled. This study was to investigate effective maintenance strategies for each of these components, focusing on preventive and predictive maintenance. Gears: Regular lubrication is also necessary to ensure smooth gear movement and prevent excessive friction that could lead to failure. Chisel Bits: Monitoring the condition of the tool blade needs to be done regularly. Toolpost: The toolpost needs to be checked periodically to ensure availability and safety of the cutting tool. Bottom and Top Slings: Maintenance of the lower and upper slings involves checking for tension and wear. C6240A type lathe users can minimize the risk of failure, improve operational efficiency, and extend the life of the machine. The method used in this research is a qualitative method, by means of observation and interviews. The results of this study are that the gears can be more durable because lubrication is always given and not easily thirsty, the tool blade is not easily blunted because the workpiece is fed little by little, and frequent honing is done to keep it sharp. The locking toolpost is not easily damaged if you use a rubber hammer when locking, the bottom row makes a change of ashock so that it can do automatic turning. This maintenance can increase the life of the lathe for longer operation.

The Ripple Mill machine is one of the vital components in a Palm Oil Mill (PKS) that functions to separate the palm kernel from its shell. This process is very important because the quality and quantity of the palm kernel produced will directly affect the economic value and production efficiency in the palm oil industry. At PTPN IV Regional II Plantation Unit and Adolina PKS, various technical problems were found that caused a decrease in machine performance, including rotor bars and square bars that experienced wear due to age and improper machine settings. In addition, other damage that often occurs is a broken van belt due to age and excessive tension, feeder motor dysfunction caused by excessive load, and motor overheating that occurs due to age and high workload. To overcome these problems, this study uses the Failure Mode and Effect Analysis (FMEA) method. This method aims to identify various potential failures, assess the severity, frequency of occurrence, and detection capability, so that the Risk Priority Number (RPN) value can be calculated as a basis for repair priorities. The results showed that worn rotor bars and worn square bars had the highest RPN values, each at 280, equivalent to 40.23% of the total identified risks. This indicates that these two components are critical points requiring immediate repair and maintenance attention. Applying FMEA in this context provides tangible benefits, including helping the company formulate a more targeted maintenance strategy, reducing the risk of recurring damage, and minimizing downtime that impacts production. With more systematic maintenance, operational efficiency can be improved while extending the lifespan of the Ripple Mill machine.

Osha Snack UMKM faces issues related to product defects, which are suspected to arise due to a lack of quality control in the production process. This study aims to identify the causes of product defects, provide improvement suggestions, and determine effective ways to control product quality. Data were collected through interviews with relevant parties and field surveys to gather information on production volume, product defects, and production activities. The data were processed by organizing it into check sheets, performing regression calculations, and analyzing it using scatter diagrams and fishbone analysis. The Statistical Process Control (SPC) method was applied to analyze, control, and improve the production process. The results show a significant relationship between production volume and the number of defective products, with the regression equation Y = 0.0764X and a coefficient of determination R² = 0.9625. The most common type of defect is broken snacks before packaging. In addition, waste products also come from product returns by buyers, which leads to raw material waste and hinders the achievement of production targets. The analysis results suggest that the UMKM should implement quality control measures in the form of process improvements, enhancement of work skills, proper machine maintenance, implementation of SOPs, and improvement of working conditions.

This study aims to analyze the causes of bottlenecks in lip balm production at PT Rumah Rumput Laut by using a survey approach and fishbone diagram analysis method. The research method used is a descriptive method with survey approach which was conducted at PT Rumah Rumput Laut, Bogor Regency, West Java. Data were collected through observations and interviews with related parties in the production process based on previously identified problems. A fishbone diagram was used to identify the factors causing bottlenecks, which were grouped into six main categories, namely: manpower, machine, method, material, measurement, and environment. The results of the fishbone diagram analysis show that bottlenecks in lip balm production are caused by the irregular flow of material transfer, long waiting time for the quality control process, and limited production capacity. To overcome this problem, it is necessary to improve the operator supervision system, implement a regular machine maintenance schedule, rearrange the production space layout, and use technology to monitor machine conditions in real time.

Occupational Health and Safety (OHS) is a crucial aspect of the textile industry to ensure worker protection and maintain smooth production processes. This study aims to identify and analyze potential occupational accident risks in the sizing machine process. The methods used in this research are Job Safety Analysis (JSA) and Risk Assessment to evaluate workplace hazards that may disrupt operations. The results indicate several major risks in the sizing process, including mechanical hazards due to direct contact with machines, ergonomic hazards caused by improper working postures, and chemical hazards from exposure to cotton dust and sizing solution vapors. The main risk factors include human aspects, the work environment, and machinery. The recommended improvements in this study include enhancing work supervision and control, providing safety training for workers, optimizing workplace ergonomics, and conducting regular machine maintenance to reduce accident risks. The proper implementation of safety strategies is expected to improve production efficiency and create a safer and more conducive work environment.

Product quality is a key factor in enhancing a company's competitiveness. PT Nugraha Potong Tekuk, a producer of MPGG products, experienced a significant increase in the defect rate, reaching 11% of total production during the period from June 24 to July 16, 2024. This study aims to analyze the defect rate, identify the main causes, and provide improvement recommendations. The study follows the Six Sigma methodology, including the Define, Measure, Analyze, Improve, and Control (DMAIC) phases. Based on P-Chart analysis, the production process is within statistical control limits, but the defect rate still requires improvement. Two main types of defects were identified: unevenness and size defects, each accounting for 50% of the total defects. Fishbone diagram analysis revealed four main contributing factors: people, machines, materials, and environment. The people factor includes lack of operator skills and operator fatigue, while the machine factor covers worn-out tools and uncalibrated measuring instruments. The material factor is related to low-quality raw materials, and the environmental factor includes poor lighting and unstable work surfaces. Improvement recommendations include operator training, routine machine maintenance, quality control of raw materials, and improvement of the work environment. This study is expected to help PT Nugraha Potong Tekuk enhance product quality, reduce defect rates, and maintain competitiveness in the market.

PT. Dian Swastatika Sentosa generates electricity through a private thermal power plant. This company produces steam and electricity for paper mills. The company hopes to meet its steam and electricity needs in 2023 with a boiler with a load capacity of 180 tons and a maximum capacity of 220 tons. However, from February to July 2023, that goal was not achieved. The most common problems faced by this company are the failure to conduct preventive inspections and timely machine maintenance, as well as the failure to carry out necessary repairs. Delays in machine repairs, which result in inconsistent machine downtime schedules to meet customer demand, leading to damage to boiler equipment, causing abnormal boiler operation and reduced steam production. This research aims to design equipment to withstand operational impacts using failure mode and effects analysis (FMEA) with the Soft Systems Methodology (SSM) and reliability-centered maintenance (RCM) techniques. The RCM method assists in identifying the processes that must be followed to guarantee that a machine or system performs as intended. RCM can also be used to design, choose, and create alternative maintenance methods that are focused on safety, operations, standards, and economics. For the entire problem in the investigation, a dynamic model is necessary. An analytical system is used in this model in order to recognize and duplicate the features of the overall system., as well as to provide repair solutions and address the burden of the problem. This research produces a presentation in the form of problem identification, causal loops, diagrams of machines that frequently experience failures, rich images of the causes and effects of the ball plate crusher liner damage, root cause definitions, and conceptual models for repair and maintenance. business productivity and debating process. 

This study aims to use the fishbone diagram as a tool to identify the causes of damage to the feeder mechanism of scrap machines and to develop Standard Operating Procedures (SOP) that can improve performance and reduce the level of damage. This diagram is used to evaluate various elements that contribute to the damage of the feeder mechanism, such as human, machine, material, method, and environmental factors. Through this evaluation, the main causes of the damage can be identified, and appropriate corrective actions can be formulated. In addition, this research also aims to design SOPs that ensure more efficient operation of the scrap machine and reduce the likelihood of operational errors. The implementation of mechanism improvements and SOPs is expected to enhance the reliability of the scrap machine, reduce downtime, and increase productivity in the mechanical technology laboratory. The findings of this study are expected to make a significant contribution to the development of management systems and equipment maintenance in both industrial and educational sectors.  

The quality of a product is built by the company by paying attention to the needs and desires of customers because an industrial factory will not exist if the products made or ordered are not in accordance with consumer desires. This study aims to determine the causes of fabric defects, especially in one of the Alaska brands in April 2023 as many as 825 defect cases. This research uses the Fault Tree Analysis (FTA) method used to analyze the causes of production defects such as underfeed, double feed, and non-standard thickness. The results of the study were found several factors causing defects in less feed, double feed, and thickness not according to standards, namely raw materials, machinery, and human factors. The improvement strategies during the production process are. Strict supervision and control, periodic training, proper machine maintenance, and selection of quality raw materials are strategies implemented to minimize fabric defects. implement supporting infrastructure to reduce product growth rates.      

PG Madukismo is a sugar factory that was established in 1955 and is the only sugar factory in the province of the Special Region of Yogyakarta. This factory is located in Padokan Village, Tirtonirmolo Village, Kasihan District, Bantul Regency, Special Region of Yogyakarta. PT Madubaru, a company engaged in sugar cane processing, is a sugar and spirits factory located in the Yogyakarta area. Companies that produce cane sugar with SHS IA quality. Product defects are often found, resulting in a decrease in quality, therefore it is necessary to carry out quality control. This study uses the Failure Mode and Effect Analysis (FMEA) method to identify failure modes, Logic Tree Analysis (LTA) to determine the consequences of failure arising from failure modes and determine effective preventive maintenance policies for each machine. For the production quality control section, the Statistical Processing Control (SPC) method is used to analyze product defects to determine whether product defects are still within controllable limits or not. While the Failure Mode and Effect Analysis (FMEA) method is used to determine the failure mode in sugar production. For the quality control section on raw materials using the Economic Order Quantity (EOQ), Re-Order Point (ROP), Safety Stock (SS), and Total Inventory Cost (TIC) methods. The conclusion of this study is regarding the results of the analysis and calculations carried out with several settlement methods and there are several causes of production defects from 5 factors, such as: human factors, work methods, environment, raw materials and machines used. And provide solutions to companies in order to reduce defects by controlling product quality.    

PT Kusuma Mulia Plasindo Infitex is a company engaged in the manufacturing sector that produces polypropylene and HD (Hight density Polyethylene) plastic products. The problem that occurred at PT Kusuma Mulia Plasindo Infitex was that the number of defective products on HD plastic products of 98,327 kg contained 4,194 kg of defective products. The purpose of this study is to determine the factors that cause defects and suggestions for improvements to minimize defective products. This study uses the six sigma method which is useful for finding the root causes of problems that are adjusted to the characteristics of the data they have. The 5 stages of six sigma are DMAIC(define, measure, analyze, improve, control) and kaizen is the Five M-Checklist. So from the results of data processing, the value is obtained in the form of DPMO 8393.048 and a sigma value of 2.49. Proposed improvements include providing training in plastic welding, providing additional 5-10 minute breaks and supervision while working. Perform routine machine maintenance every month and cleaning every day. Adding ventilation and blowers in the production room. Carry out the production process according to the existing SOP at the company, especially in mixing materials according to the SOP for raw materials that have been made by the company.

In an effort to increase productivity to ensure smooth production processes, it is necessary to implement an appropriate maintenance system to reduce production machine downtime. The purpose of company maintenance is to keep production machines in good condition so that production operations can run efficiently and effectively. PT Yale Woodpallet Indonesia is a company in Indonesia that produces wooden pallets (wood pallet). This company often experiences problems with damage to machines due to suboptimal machine maintenance because the maintenance system is carried out to repair damaged components with new components resulting in downtime. Among these problems, this study aims to determine maintenance intervals to minimize maintenance costs by using modularity design and age replacement methods. Based on the analysis of the results obtained, it is known that the modularity design and age replacement methods can achieve optimal component replacement intervals for pallet machine components is 30,000 minutes, rotary screening components are 33,200 minutes and hopper components are 33,200 minutes. The total maintenance cost per year is Rp. 2,115,610,959, -. compared to the company's maintenance costs which have a value of Rp. 2,668,692,000, the maintenance system using the modularity design and age replacement method is more efficient by 1.27%.

Developments in the industrial world are increasingly rapid, resulting in increased competition in the industrial world, so that industrial companies are competing to improve production efficiency and effectiveness. Especially companies in the manufacturing sector, increasing productivity in a production system is an absolute thing that must be done. One of the main indicators in increasing productivity is the level of rehabilitation of production machines at the company. In measuring how good the rehabilitation of a production machine is, an effective and efficient maintenance maintenance process is needed for the company. Continuous use of the machine will decrease the level of readiness of the machine itself. In an effort to maintain the level of machine readiness so that production results are guaranteed due to continuous use of the machine, regular machine maintenance and maintenance activities are needed which are expected to prolong the condition of production machines so that they are not damaged, in case of machine damage it can disrupt production activities.

Community Service is an obligation for lecturers to carry out the Tridharma of Higher Education. The activity was carried out on June 18, 2022 in Jelamung RT 05 RW 02, Kemujan Karimujawa which was attended by 12 participants. The purpose of this service is to know how to maintain fishing boat outboard engines in general, which is used to change the engine oil, cleaning the air filter and fuel filter, testing the injectors and adjusting the valves, in addition it is to know the reason why the engine cannot start. Therefore, someone should check the fuel flow, opening the fuel filter and cleaning it. The implementation of this program is for fishermen’s beneficial, hance they can maintain and overcome engine damage for the sake of progress and increase the income.

PT. AIC uses a manual system in engine maintenance management. This makes it difficult to access in measuring the rate of damage, for acceleration information in maintenance management. This problem requires an identification to provide an effective machine maintenance management information system. The MTBF value will be able to detect machine damage, especially the piccanol gamma loom machine. The MTBF value can see the damage to the machine by looking at the condition of the machine, the data history of machine damage, the number of machine failures that occurred in a certain period. The MTBF value of the machine can control the reliability and know the life of the machine. Action maintenance can be done before the machine is damaged. After calculating the MTBF value of the piccanol gamma loom machine, it is still relatively small so the machine is still often damaged.