INTEGRASI MONITORING OEE REAL-TIME BERBASIS PLC-HMI DAN ANALISIS LOG GRANULAR UNTUK OPTIMASI PRODUKSI
DOI:
https://doi.org/10.26623/elektrika.v18i1.14252Kata Kunci:
IIoT, OPC Server, Monitoring real-time, Industri Pintar, Penyangga GandaAbstrak
Overall Equipment Effectiveness (OEE) merupakan metrik krusial dalam manufaktur modern, namun sistem monitoring konvensional seringkali hanya berfokus pada pelaporan agregat tanpa kemampuan identifikasi akar penyebab masalah secara otomatis. Penelitian ini mengembangkan sistem monitoring OEE real-time terintegrasi menggunakan PLC Schneider dan HMI Weintek melalui OPC Server (KEPServerEX) dengan mekanisme Double-Buffer Persistency. Berbeda dengan metode tradisional, penelitian ini memperkenalkan analisis event-log granular untuk membedah data produksi pada resolusi milidetik. Sistem yang dibangun berhasil mencapai keandalan transmisi data sebesar 100% bahkan pada output puncak sebanyak 58.063 unit per hari. Hasil analisis mengungkap adanya trade-off kritis antara performa dan kualitas: akselerasi cycle time ekstrem hingga 0,552 detik memicu lonjakan signifikan pada Type 2 Rejects (kegagalan ejektor) yang menyumbang 71,86% dari total kerugian kualitas. Anomali mikro ini divalidasi secara fisik sebagai pelanggaran batas mechanical dwell time. Dengan mengidentifikasi Safe Operating Window antara 0,630 detik – 0,635 detik dan menerapkan usulan strategi speed capping, penelitian ini memproyeksikan peningkatan nilai OEE melalui keseimbangan antara kecepatan dan stabilitas proses. Temuan ini memberikan kontribusi ilmiah berupa referensi teknis bagi penerapan pengendalian kecepatan adaptif berbasis umpan balik kualitas real-time pada lini perakitan otomatis.
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