Analysis of Downtime Causes and Proposed Belt Conveyor Performance Improvement Using Root Cause Analysis and Plan-Do-Check-Action Methods at PT X

Muhammad Rafi Ardyanto; Sinta Dewi

doi:10.59934/jaiea.v6i1.2668

Authors

Muhammad Rafi Ardyanto UPN "Veteran" Jawa Timur
Sinta Dewi Teknik Industri, Universitas Pembangunan Nasional “Veteran” Jawa Timur

DOI:

https://doi.org/10.59934/jaiea.v6i1.2668

Keywords:

Availability; Belt Conveyor; Downtime; Fishbone Diagram; PDCA; Preventive Maintenance; Root Cause Analysis

Abstract

This study analyzes the causes of downtime and proposes performance improvement solutions for Belt Conveyor machines at PT X using an integrated approach of Root Cause Analysis (RCA) and Plan-Do-Check-Action (PDCA) methods. Operating in the tobacco processing industry in Mojokerto, East Java, PT X faces significant production inefficiency challenges, with Belt Conveyors (M-08) contributing 47.09% of total downtime (103.93 hours) in March 2025. The research employs Pareto Diagram to identify priority problems and Fishbone Diagram to map root causes across six factors: Machine, Method, Man, Material, Measurement, and Environment. Analysis reveals that the dominant causes are jammed roller idlers and motor overheating due to tobacco dust accumulation. The 5W+1H method is utilized to formulate corrective and preventive actions, including upgrading bearings to Rubber Sealed type (6204-2RS) and establishing systematic motor cleaning procedures. Implementation results project a 50% downtime reduction from 103.93 hours to 52 hours, with machine availability increasing from 98.51% to 99.26%. The study demonstrates that integration of RCA and PDCA provides an effective framework for identifying root causes and implementing sustainable maintenance solutions. Standardization of component specifications and cleaning procedures is established to ensure continuous improvement and optimal operational performance in tobacco processing operations.

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