ANALISIS TOTAL PRODUCTIVE MAINTENANCE PADA TURNTABLE VIBRRATING COMPACTOR GUNA MEMPERBAIKI KINERJA PERUSAHAAN PT. INDONESIA ASAHAN ALUMINIUM (Persero)

ANALISIS TOTAL PRODUCTIVE MAINTENANCE PADA TURNTABLE VIBRRATING COMPACTOR GUNA MEMPERBAIKI KINERJA PERUSAHAAN PT. INDONESIA ASAHAN ALUMINIUM (Persero)

SKRIPSI

Skripsi Yang Diajukan Untuk Melengkapi Syarat Memperoleh Gelar Sarjana Teknik

Oleh :

TRABANASIA THERAH SITORUS NIM : 110401078

DEPARTEMEN TEKNIK MESIN FAKULTAS TEKNIK UNIVERSITAS SUMATERA UTARA MEDAN 2016

Universitas Sumatera Utara

ANALISIS TOTAL PRODUCTIVE MAINTENANCE PADA TURNTABLE VIBRRATING COMPACTOR GUNA MEMPERBAIKI KINERJA PERUSAHAAN PT. INDONESIA ASAHAN ALUMINIUM (Persero)

DISUSUN OLEH : TRABANASIA THERAH SITORUS 110401078

Medan, 18 Maret 2016 Penulis,

Trabanasia Therah Sitorus NIM: 110401078 ii


ABSTRAK

Total Productive Maintenance (TPM) merupakan ide Nakajima (1988) yang menekankan pada pendayagunaan dan keterlibatan sumber daya manusia dan sistem Preventive Maintenance untuk memaksimalkan efektifitas peralatan dengan melibatkan semua departemen dan fungsional orgnisasi. Studi penerapan TPM di Pabrik Anoda PT. INALUM (Persero) ini bertujuan untuk mengukur efektifitas mesin Turntable Vibrating Compactor. Didalam analisis TPM dengan menggunakan metode OEE ini ada terdapat enam penyebab kerugian yang disebut dengan Six Big Losses yaitu diantaranya : Kerusakan peralatan (Breakdown Losses), Persiapan peralatan (Set-up and Adjustment), Gangguan kecil dan waktu nganggur (Idling and Minor Stoppages)Kecepatan rendah (Reduced Speed Losses), Cacat produk dalam proses (Rework Losses), Hasil rendah (Yield/Scrap losses). Kesimpulan yang didapat adalah nilai rata – rata OEE selama periode April 2015 - Maret 2015adalah 63,65 % masih dibawah standar. Nilai Idling/Minor Stoppages Losses 15,18% dengan total waktu 942,51 jam, hasil Rework Losses0,02 % dengan total waktu 39,82jam, hasil Reduce Speed Losses 27,47% dengan total waktu 2120,69jam, hasil Breakdown Losses 7,75% dengan total waktu 51,20 jam, hasil Setup and Adjustment Losses 0,81 % dengan total waktu 57,31jam, hasil Yield/Scrap lossesdidapat 0. Kata kunci : Overall Equipment Efectiveness, Availability, Breakdown Time, Rate of Quality Product, Six Big Losses

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ABSTRACT

Total Productive Maintenance (TPM) is an idea Nakajima (1988), which emphasizes the empowerment and involvement of human resources and Preventive Maintenance System to maximize the effectiveness of the equipment by involving all departments and functional society together. Study of the application of TPM in Anode Plant PT. INALUM (Persero) is intended to measure the effectiveness of Turntable Vibrating Compactor machine. In the analysis of TPM using OEE there are six causes of loss of the so-called Six Big Losses of them: Damage to equipment (Breakdown Losses), Preparation of equipment (Set-up and Adjustment), disorders of the small and idle time (Idling and Minor Stoppages) low speed (Speed Reduced losses), Defective products in the process (Rework losses), lower results (Yield / Scrap losses). The conclusion is the value - average OEE during the period April 2015 - March 2015 is 63.65% is below standard. Value Idling / Minor Stoppages Losses 15.18% with a total time of 942.51 hours, the results Rework Losses of 0.02% with a total time of 39.82 hours, the results Reduce Speed Losses 27.47% with a total time of 2120.69 hours, the results breakdown losses of 7.75% with a total time of 51.20 hours, the results Setup and Adjustment losses of 0.81% with a total time of 57.31 hours, the results Yield / Scrap losses obtained 0.

Keywords: Overall Equipment Efectiveness, Availability, Breakdown Time, Rate of Quality Product, Six Big Losses

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KATA PENGANTAR

Puji dan syukur penulis panjatkan ke hadirat Tuhan Yang Maha Esa karena hanya atas berkat dan karunia-Nya penulis dapat mengerjakan dan meyelesaikan skripsi ini dengan baik. Skripsi ini merupakan salah satu syarat untuk menyelesaikan pendidikan untuk mencapai gelar sarjana di Departemen Teknik Mesin Fakultas Teknik Universitas Sumatera Utara. Adapun yang menjadi judul skripsi ini yaitu “Analisis Total Productive Maintenance pada Turntable Vibrating Compactor guna Memperbaiki Kinerja Perusahaan.” Penulis berterima kasih kepada banyak pihak yang telah banyak membantu penulis di berbagai hal dalam proses penyusunan skripsi ini. Oleh sebab itu, penulis menyampaikan terima kasih kepada: 1. BapakIr. Alfian Hamsi, M.Sc., selaku Dosen Pembimbing yang telah memberikan banyak bimbingan, arahan, dan masukan yang positif kepada penulis selama penyusunan skripsi ini 2. Bapak, selaku Dosen Pembanding yang telah memberikan banyak saran untuk perbaikan selama proses penyusunan skripsi ini. 3. Bapak Dr.Ing.Ir.Ikwansyah Isranuri, selaku Ketua Departemen Teknik Mesin Fakultas Teknik USU. 4. Bapak/Ibu Staff Pengajar dan Pegawai di Departemen Teknik Mesin USU. 5. Kedua orang tua penulis Amson Harnold Sitorus dan Anny Juniar Hutagaol, yang selalu memberikan doa dan dukungan berupa moral maupun materi, yang selalu memberi semangat dan arahan dalam bersikap selama proses penyusunan skripsi ini. 6. Teman sekelompok bimbingan penelitian, Febri Agustinus Ginting atas kerjasama yang baik dalam proses bimbingan selama ini.

7. Orang tua dan keluarga besar penulis yang telah memberikan doa, semangat, dan materil selama proses penyusunan skripsi ini. 8. Seluruh teman-teman penulis, baik teman satu angkatan 2011.

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Penulis mengharapkan kritik dan saran yang membangun dari berbagai pihak. Penulis juga mengharapkan skripsi ini dapat menjadi tambahan pengetahuan bagi pembaca dan bermanfaat untuk kita semua. Terimakasih.

Medan, Juli 2016

Trabanasia Therah Sitorus

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DAFTAR ISI

ABSTRAK ...................................................................................................... i KATA PENGANTAR .................................................................................... iii DAFTAR ISI ................................................................................................... v DAFTAR GAMBAR ...................................................................................... viii DAFTAR TABEL .......................................................................................... x DAFTAR PERSAMAAN............................................................................... xii DAFTAR NOTASI ......................................................................................... xiii BAB I PENDAHULUAN...............................................................................1 1.1. Latar Belakang ............................................................................. 1 1.2. Permasalahan ................................................................................ 1 1.3. Tujuan Penelitian.......................................................................... 2 1.4. Batasan Masalah ........................................................................... 2 1.5. Manfaat Penelitian........................................................................ 2 1.6. Metodologi Penulisan ................................................................... 2 1.7. Sistematika Penulisan ................................................................... 3 BAB II GAMBARAN UMUM PERUSAHAAN DAN OBJEK PENELITIAN................................................................... ................ 5 2.1. Alur Produksi PT. Inalum (persero) .............................................. 5 2.2.Mesin Vibrating Compactor........................................................... 13 2.2.1.Vibrating Compactor Secara Umum ........................................ 13 2.2.2.Vibrating Compactor yang Digunakan PT. Inalum (persero) .. 17 2.2.3.Komponen-komponen Utama Turntable Vibrating Compactor18 BAB II LANDASAN TEORI................................................................... ..... 24 3.1. Total Productive Maintenance (TPM) .......................................... 24

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3.1.1.Definisi Total Productive Maintenance (TPM) ........................ 24 3.1.2.Keuntungan TPM ...................................................................... 25 3.2. Pengertian dan Tujuan Maintenance ............................................. 26 3.2.1.Pengertian Maintenance............................................................ 26 3.2.2. Tujuan Maintenance ................................................................ 27 3.3. Pembagian Maintenance ............................................................... 28 3.3.1.Pemeliharaan Terencana (Planned Maintenance) .................... 28 3.3.2.Pemeliharaan Tak Terencana (Unplanned Maintenance)......... 31 3.4.Perawatan Mandiri (Autonomous Maintenance) ............................ 31 3.5.OEE (Overall Equipment Effectiveness) ........................................ 33 3.6.Analisis Produktivitas : Six Big Losses (Enam Kerugian Besar) ... 38 BAB IV METODOLOGI PENELITIAN.....................................................40 4.1 Tempat dan Waktu Penelitian ........................................................ 40 4.1.1 Tempat Penelitan ...................................................................... 40 4.1.2 Waktu Penelitian ....................................................................... 40 4.2 Rancangan Penelitian ..................................................................... 40 4.3 Objek Penelitian ............................................................................. 40 4.4 Instrumen Penelitian ....................................................................... 40 4.5 Pelaksanaan Penelitian .................................................................. 40 4.6. Pengolahan Data ............................................................................ 41 4.7. Analisis Data dan Pemecahan Masalah ......................................... 44 BAB V PENGOLAHAN DAN ANALISA DATA......................................46 5.1. Pengumpulan Data ........................................................................ 46 5.1.1. Data waktu downtime .............................................................. 46 5.1.1. Planned Downtime ................................................................... 47 5.1.3. Data Waktu Setup .................................................................... 48

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5.1.4. Data Waktu Produksi ............................................................... 49 5.2. Pengolahan Data ............................................................................ 51 5.2.1. Perhitungan Avalability ........................................................... 51 5.2.2.Perhitungan Performance Efficiency ........................................ 53 5.2.3.Perhitungan Rate Of Quality Product (RQP)............................ 55 5.2.4.Perhitungan Overall Equipment Effectiveness (OEE) .............. 56 5.2.5.Perhitungan Six Big Losses ....................................................... 58 5.3.Analisa Perhitungan ....................................................................... 68 5.3.1.Analisa perhitungan Overall Equipment Effectiveness (OEE) . 68 5.3.2.Analisa perhitungan OEE Six Big Losses ................................. 70 5.4.Analisa diagram sebab akibat (Fish Bone Diagram) ..................... 73 5.5.Usulan pemecahan masalah ........................................................... 75 5.5.1.Usulan penyelesaian masalah Six Big Losses ........................... 75 5.5.2.Penerapan Total Productive Maintenance (TPM) .................... 76 BAB VI KESIMPULAN DAN SARAN........................................................78 6.1. Kesimpulan.................................................................................... 78 6.2. Saran .............................................................................................. 79 DAFTAR PUSTAKA ..................................................................................... xiv LAMPIRAN .................................................................................................... xv

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DAFTAR GAMBAR Gambar 2.1 Single Sliding Table Vibrating Compactor ........................................14 Gambar 2.2. Tandem Sliding Table Vibrating Compactor ....................................15 Gambar 2.3 Triple Sliding Table Vibrating Compactor ........................................16 Gambar 2.4. Turntable Vibrating Compactor ........................................................17 Gambar 2.5. Turntable Vibrating Compactor di PT. Inalum (persero) ..................18 Gambar 2.6. Paste Spreading Device ....................................................................19 Gambar 2.7. HopperScale ......................................................................................19 Gambar 2.8. Vibrating Table With Unbalance Drive ............................................20 Gambar 2.9. Clamp Locking Device for Mould .....................................................21 Gambar 2.10. Pushing Device ................................................................................22 Gambar 2.11. Mould ..............................................................................................22 Gambar 2.12. Vacuum System................................................................................23 Gambar 3.1. Overall Equipment Effectiveness ......................................................33 Gambar 4.1. Tahapan proses pemecahan masalah .................................................44 Gambar 4.2 Diagram alir perhitungan Overall Equipment Effectiveness (OEE)...45 Gambar 5.1. Total Produksi (blok) mesin Turntable Vibrating Compactor periode April 2015 – Maret 2016 ...................................51 Gambar 5.2. Diagram Availability mesin Turntable Vibrating Compactor...........53 Gambar 5.3. Diagram Performance Efficiency ......................................................55 Gambar 5.4. Diagram Rate of Quality Product......................................................56 viii


Gambar 5.5. Diagram perolehan OEE mesin Turntable Vibrating Compactor selama periode April 2015 – Maret 2016 ..........................................58 Gambar 5.6. Diagram Equipment Failure/Breakdown Lossperiode April 2015 Maret 2016 ........................................................................................60 Gambar 5.7. Diagram Setup and Adjustment losses periode April 2015 - Maret 2016 ...................................................................62 Gambar 5.8. Diagram Idling and Minor Stoppages Lossesperiode April 2015 - Maret 2016 ...................................................................64 Gambar 5.9. Diagram Reduce Speed LossesMesin Turntable Vibrating Compactor ........................................................................65 Gambar 5.10. Diagram Rework losses untuk periode April 2015 –Maret 2016 ....67 Gambar 5.11. Grafik Perbandingan OEE Mesin Turntable Vibrating Compactor periode April 2015-Maret 2016 dengan Standar JIPM (Japan Institute Of Plant Maintenance) .......................................................69 Gambar 5.12. Diagram persentase Six Big Losses .................................................71 Gambar 5.13. Diagram Sebab Akibat (Fish Bone) ................................................73

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DAFTAR TABEL Tabel 3.1. World Class OEE ..................................................................................37 Tabel 5.1. Data waktu kerusakan mesin Turntable Vibrating Compactor ............47 Tabel 5.2. Data waktu pemeliharaan mesin Turntable Vibrating Compactor .......48 Tabel 5.3. Data waktu Set Up mesin Turntable Vibrating Compactor ..................49 Tabel 5.4. Data Produksi Turntable Vibrating Compactor periode April 2015 – Maret 2016 ..........................................................50 Table 5.5. Availability mesin Turntable Vibrating Compactor pada periode April 2015 – Maret 2016 .................................................................................52 Tabel 5.6. Performance Efficiency periode April 2015 – Maret 2016 ...................54 Tabel 5.7 Perhitungan Rate of quality product periode April 2015 – Maret 2016 56 Tabel 5.8. Nilai Overall Equipment Effectiveness (OEE) mesin Turntable Vibrating Compactor periode April 2015 – Maret 2016 ......57 Tabel 5.9. Equipment Failure/Breakdowns (EF) periode April 2015-Maret 2016 ..........................................................................59 Tabel 5.10. Setup and Adjustment losses Periode April 2015-Maret 2016 ............61 Tabel 5.11. Idling and Minor Stoppages Losses untuk periode April 2015 - Maret 2015 .......................................................................................................63 Tabel 5.12. Reduce speed losses untuk periode April 2015 – Maret 2016 ............65 Tabel 5.13. Rework losses untuk periode April 2015 –Maret 2016 .......................67

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Tabel 5.14. Persentase pencapaian mesin Turntable Vibrating Compactor periode April 2015 – Maret 2016 .......................................................................69 Tabel 5.15. Persentase Faktor Six Big LossesMesin Turntable Vibrating Compactor periode April 2015 – Maret 2016 .......................................70 Tabel 5.16. Perbandinganrata-rata Six Big LossesMesin Turntable Vibrating Compactor .............................................................................................72 Tabel 5.17. Usulan penyelesaian masalah Six Big Losses .....................................75

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DAFTAR PERSAMAAN Persamaan 3.1 : Overall Equipment Efectiveness (OEE).......................................34 Persamaan 3.2 : Availability (AV) .........................................................................34 Persamaan 3.3 : Loading Time ...............................................................................35 Persamaan 3.4 : Operation Time ............................................................................35 Persamaan 3.5 : Downtime .....................................................................................35 Persamaan 3.6 : Operation Speed Rate ..................................................................35 Persamaan 3.7 : Net Operation Rate ......................................................................36 Persamaan 3.8 : Performance Efficiency (PE) .......................................................36 Persamaan 3.9 : Rate of Quality Product (RQP)....................................................36 Persamaan 5.1 : Equipment Failure/Brealdowns (EF) ..........................................59 Persamaan 5.2 : Setup and Adjustment loss (SA) ..................................................61 Persamaan 5.3 : Idling and Minor Stoppages Losses (IMS) ..................................62 Persamaan 5.4 : Non Productive Time ...................................................................63 Persamaan 5.5 : Reduce Speed Losses(RS) ............................................................64 Persamaan 5.6 : Rework Loss (RL) ........................................................................66

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DAFTAR NOTASI KN

= KO-Kneader

SM

= Shaking Machine

PH

= Pre-Heater

AV

= Availability

PE

= Performance Efficiency

RQP

= Rate of Quality Product

OEE

= Overall Equipment Efectiveness

TPM

= Total Productive Maintenance

PM

= Planned Maintenance

EF

= Equipment Failure/Breakdown

SA

= Setup and Adjustment loss

IMS

= Idling and Minor Stoppages loss

RS

= Reduce Speed

RL

= Rework Loss

JIPM

= Japan Institute of Plant Maintenance

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ANALISIS TOTAL PRODUCTIVE MAINTENANCE PADA TURNTABLE VIBRRATING COMPACTOR GUNA MEMPERBAIKI KINERJA PERUSAHAAN PT. INDONESIA ASAHAN ALUMINIUM (Persero)

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