THE EXISTING PROBLEM

Employees Safety Problems

Safety of employees in the company is still lack of attention. The production floor that

does not have clear rules of safety standards such as the absence of signs to should use safety
helmets, or signs should use shoes when production takes place and so on. In this company, there
is no information about any safety tool that should be used while on the production floor. In
general, in a company, there should be warnings or alerts regarding the use of helmets and other
safety equipment while on the production floor. It is dangerous in case of work accidents due to
lack of safety equipment worn by employees.

Auxiliary Storage
Inside the storage of PT Metaltama Perkasa plant, is found that there is a problem in the

auxiliary storage. In this portion of auxiliary goods, is it visible that there is an irregular storage
system and there is no access point to enter the inside of the auxiliary storage.
The auxiliary goods that exist inside the storage, are placed irregularly and untidy that
caused taking out the goods is very difficult. It will take a long time to find a certain goods and
the difficulty to access to the goods itself because there is no access point.

Storage Area of Finished Goods

In addition to storage problems auxiliary materials, finished goods storage was

problematic because the half of the finished goods are put into production floor area because the
finished goods area is already full. Besides of making a mess, the production floor was disrupted

mainly to make the transition from one process to another, especially in the transition of the
forming to polishing machine.

Production
Production target in PT Metaltama Perkasa is never reached. The target is to produce 2.5

ton per day, but the production is only reaching 2 ton per day and there is also a problem when
moving goods from the forming machine and polish machine, in which the transition is only
made by 2 of their employees in which for every 1 pipe is can only carried by one person. In the
plants, there are 2 kind of the production machine used, the forming machine and polish
machine, there are 7 forming machine and 4 polish machine in the plant. Forming machine is a
lot more because the polish machine works much faster than the forming machine

THE HANDLING OF THE PROBLEMS BY THE MANAGEMENT

These are handlings that been done to deliver desired performance by the plant:
1. To solve the health and safety environments problems
The plant need to make some warning signs to encourage the employee to use safety
equipment inside the plant.
2. To solve the auxiliary storage problems
It is needed to place some cabinet or racks to tidying up the goods so that the employee can
easily find the goods to continue the production process and to recalculate the space needed
to ensure future building development process of resizing the entire storage warehouse.
3. To solve the finished goods storage problems

Because the storage itself have difficulties of placing all the goods inside the storage, we
need to calculate again for future expansion of the finished goods so it will able to store all
the finished goods inside.
4. To solve production problems
The plant need to add some additional machine if possible to greatly reach the targeted
production of 2.5 ton per day. Also to add some employees to transfer goods from the
forming machine to polish machine so it can carry more of the goods that can give some gain
in performance of transition of the processed goods.

ANALIZING PREVIOUS PROBLEMS AND

IDENTIFYING POTENTIAL CAUSES

The handling made by the management itself may fixed some of the problems. But it
would be more efficient if we can identify the problems by analyzing the causes that made the
problems exist. This can be done by using a fishbone diagram in each section of the problem.
Identifying from the perspective of human, machinery, methods, environment, and the
measurement in which we can find out what is the potential cause that ended creating a problem
in the production process. If we not analyzing each of the problems efficiently, we can encounter
another one later in the future.

Employees Safety Problems:

For this kind of problem, we can analyze it with some theories or philosophy of employee
safety problem. The first we can find is with the Definition of Health and Safety Environment
(K3) according to OHSAS 18001:2007, Health and Safety Environment (K3), is all the
conditions and factors that may have an impact on occupational safety and workers health as
well as others (contractors, suppliers, visitors and guests) in the workplace.
Definition of Health and Safety Environment (K3) according to Mangkunegara
philosophy is a thought and effort to ensure the integrity, physical, and spiritual perfection of
labor in particular and people in general as well as the work and culture towards a fair and
prosperous society.
According to Mangkunagara (2002, p.165) that the purpose of occupational safety and
health are as follows:
1. So, that every employee is guaranteed safety and health both physically, socially, and
psychologically.
2. So, that any equipment and work equipment used as well as possible and selective as
possible.
3. For maintained production security.
4. In order to guarantee the maintenance and improvement of the nutritional health of
employees.
5. In order to heighten the excitement, harmony, and work participation.
6. To avoid health problems caused by the environment or the working conditions.
7. So, that every employees feel safe and secure in their work.
In addition to the theory, it turns out the government has also made laws that regulate
health and safety at work one of them is Law No. 1 Year 1970 on Work Safety. This law clearly
regulates the obligations of the leadership of workplaces and workers in implementing workplace
safety.

It can be concluded from the theory and the law, that lack of attention to safety problem
in this plant is a problem from inside the plant.
So, it is true to place some sign in every corner on the production floor inside the plant,
but the employees need to get some learning or training about the importance of the safety
equipment and the cause when safety equipment is not used. The regulation of using the safety
equipment inside must be emphasized, can be done by giving a punishment if the employees
disobeyed the regulation. This will make every employee become more obedient about them self
with safety equipment. All of this are important for the safety of every employee and to prevent
some accident happening in the future that can caused more of the production problems that
maybe more critical than before. When the employee is already trained and learned about the
safety of their works, eventually the employee itself will be much more careful when they doing
their jobs and also the employee will be more professional with their jobs.

Auxiliary Storage Problems

In this problem, we can use the fishbone diagram to determine which one is the culprit about the
storage problem.

Below is the fishbone diagram to find the cause about this problem:

1. Human
Starting from human section, we can determine the potential cause that the employees of PT
Metaltama Perkasa is not good in taking care of the auxiliary material storage. Because the
storage is left untidy. To counter this problem the plant need to give some briefing to the
employee about the tidiness of the storage, so the employee will understand that storage
cleanliness and tidiness is important so that they can find auxiliary goods easily which will
help a lot to gain employee performance in the production process.
2. Machines
From this we know that the potential cause is an absence of arrangements tools inside the
auxiliary storage like a cabinet or rack to place the goods in a better order. Placing this
cabinet and rack will help a lot to organize the auxiliary goods that can maintain the
cleanliness of the storage warehouse. The cabinet itself can be place stacked in another
cabinet to save more space and with more space, they can also create some access point to
pick up all the goods needed in the production process.
3. Methods
The methods used to store goods inside the auxiliary storage is still unstructured. Because the
auxiliary goods are not placed in a specific order. Even these goods are scattered around the

floor. To counter this cause, they may need to create a block for every cabinet placed in a
specific order, so itll be more easy to pick up some of the goods for production process.
4. Material
The material itself (auxiliary goods) is irregularly shaped, so there is a difficulty in stacking
the goods. This cause can be combined with placing the goods in the cabinet so it can be
stacked easily to save some spaces.
5. Measurement
The measurement for this storage room is not accurate in which we need to have a larger
room to be able to place some of the goods. Meanwhile, the small sized storage is causing the
room to looks cramped. The plant needs to consider of expanding a little bit more of the
storage warehouse size. This needs to be considered because with a larger place, it can give
some employees spaces to works more efficiently compared to a cramped place filled with
scattered goods which can slow down the production process.

Finished Goods Storage Problems

Below is the fishbone diagram to find the problem about this case:

1. Measurement

We found out that the inaccuracy of measurement for this storage room is one of the potential
cause. We know that it is important to measure correctly to equalize the function and the size
of the storage room. Finished goods will be the one that needs to be placed correctly to
ensure the quality of the product. But, when the storage room is already filled with finished
goods and the production need to keep on going, we cannot place the finished goods in any
place or just put it on the floor. The quality of the product may get defect if not carefully
handled and placed. Therefore, making a bigger storage to safely placed the finished goods is
important to maintain the quality and to keep the production process going.

Production Problems

These issues are important because the company cannot met production targets and eventually
the company may lose money because it cannot fulfill the market demand.
Below is the fish bone diagram to identify the causes of the problem:

1. Human

PT Metaltama Perkasa is doing a lot of production works, this may become some potential
cause of the unmet production target. Sometimes the employees are facing a difficulty when
doing their jobs, because there is a lot of production works to do. Therefore, in human
segment of the diagram the plant itself is lacking of the employees. The company need to
consider adding more employees to boost the production process time and also the
performance.
2. Machines
There are 2 kind of the production machine used, the forming machine and polish machine,
there are 7 forming machine and 4 polish machine in the plant. Forming machine is a lot
more because the polish machine works much faster than the forming machine. From this we
know that lack of machine is the possibility that this plant is never reach their target and can
also become the potential cause. If the company adding more machine, it may solved their
production problems and eventually can met their target.
3. Methods
The production method of this stainless pipes is not the one causing the problem, but the
method used of transferring material from forming to polishing is still using 2 of their
employees to carry it through. And 1 pipe is only carriable by 1 person. And of course, this
transferring method will caused major slowdown in the whole production. The plant should
consider adding a transferring machine like forklift that can transfer a lot of the pipes
simultaneously between the forming and polishing machine. That can save a lot of effort and
will be much faster than carrying it one by one by their employee.

IV.Conslusion
1. The first problem is the safety of employees no less attention. There are no signs or
warnings for the use of safety equipment at the time was on the production floor. The idea

given to the company was making signs or warnings concerning the use of safety
equipment on the production floor.
2. The second problem can be seen from the warehouse storage adjuvant excipients. This
warehouse looks very messy and access to take things (especially the rear) quite difficult
because all the supporting material stacked and do not leave the path. The proposal given
to the company is the manufacture of tools on auxiliary materials warehouse, which is
like a closet or shelves for storage which is more organized and more efficient space
utilization. In addition the company also needs to give insight to employees about the
importance of tidiness in the warehouse.
3. The third issue contained in the storage of finished goods. Area final products do not fit
store all finished goods that have been produced. While laying on finished goods that do
not fit interfere with the course of production. The proposal given to the plant on the
problem of storage of goods so this is a company needs to make finished goods area
wider or use tools for storage that can carry more pipes at once.
4. The fourth problem can be seen from the production companies that are not able to reach
the target. It can be caused by a shortage of employees, poor layout, traffic disruptions
due to material handling finished goods are placed in areas of production (for finished
goods area is not fit to accommodate all finished goods), and no material handling tools.
The proposal in this matter is the company should consider the addition of employees,
adding machines, and consider the use of material handling tools for the removal process
during production.
Advice :

1. Companies are advised to use simulation methods to be able to determine the best
improvements to do (most significant benefit to the improvement of the plant).

2. Companies need to provide safety equipment for employees to work security tool used all
employees have the same standards.