Reducing Overhaul Time of Coating Equipment with Seven Tools Method in PT XYZ

This study aims to improve the overhaul time efficiency of coating equipment at PT XYZ, which is a crucial part of the steel sheet galvanizing process. Inefficient overhaul processes can lead to significant downtime, affecting the company’s productivity and profitability. The study identifies factors contributing to prolonged overhaul times and provides solutions to enhance time efficiency through the application of the Seven Tools method. The research employs a qualitative approach with a case study methodology. Data were collected from the Maintenance Department of PT XYZ from February to May 2024, through interviews with technicians and maintenance managers, as well as historical data on overhaul times and maintenance frequency. Analysis was conducted using cause-and-effect diagrams (fishbone), Pareto charts, and process flow analysis. The results indicate that the frame cleaning process using a burner takes the longest time, specifically 17 hours. The primary causes are insufficient burner operation training for workers and the use of only one burner. Proposed solutions include operator training and the addition of burners to expedite the frame cleaning process simultaneously on both sides. Implementing these solutions successfully reduced the overhaul time from 60 hours to 50 hours, a 17% reduction. This research contributes to improving maintenance process efficiency in the manufacturing industry, offering practical solutions to enhance productivity and competitiveness.