Analisis Keandalan Sistem Otomasi Pallet Dispenser Berbasis PLC Siemens S7 dengan Metode FMEA dan Modifikasi Ladder Diagram untuk Otomasi Conveyor di Area Carton Box PT Indah Kiat Pulp & Paper Tbk.

The Automation Pallet Dispenser system in the Carton Box Area of PT Indah Kiat Pulp & Paper Tbk. is an Automation system used to support the distribution and transfer of Pallets during the production process. System reliability is highly influenced by the condition of control components, sensors, actuators, and Conveyor drive systems. Failures in these components can disrupt the Pallet transfer process and increase the potential for downtime. This study aims to analyze potential failures in the Automation Pallet Dispenser system using the Failure Mode and Effects Analysis (FMEA) method, as well as to provide improvement recommendations and control system development through the addition of a Ladder diagram to the Siemens S7 PLC. FMEA analysis was conducted by identifying Failure Modes, Failure causes, Failure effects, and assessing Severity, Occurrence, and Detection to determine the Risk Priority Number (RPN). The analysis results show that the Photoelectric sensor has the highest RPN value of 27, making it the main priority for improvement. Sensor failures are caused by improper Pallet positioning, which may result in the Pallet colliding with the sensor and disrupting Pallet Detection. The recommended improvements include installing a sensor guard, adjusting the sensor position, and aligning the Conveyor path.
In addition, a proposed Ladder diagram was designed to automate Conveyor 1, which was previously operated manually, by implementing an interlock system with Conveyor 2 and Conveyor 3. This proposed modification is expected to reduce operator dependency, prevent Pallet accumulation, and improve the reliability and efficiency of the Automation Pallet Dispenser system.