DAFTAR ISI
ABSTRAK ..................................................................................................................... i ABSTRACT .................................................................................................................... ii KATA PENGANTAR ................................................................................................. iii DAFTAR ISI ................................................................................................................. v DAFTAR GAMBAR ................................................................................................... ix DAFTAR TABEL ......................................................................................................... x DAFTAR LAMPIRAN ................................................................................................ xi BAB I PENDAHULUAN ............................................................................................. 1 1.1 Latar Belakang Masalah ...................................................................................... 1 1.2 Rumusan Masalah ............................................................................................... 2 1.3 Tujuan Penelitian ................................................................................................. 3 1.4 Batasan Masalah .................................................................................................. 3 1.5 Manfaat Penelitian ............................................................................................... 3 1.6 Sistematika Penulisan .......................................................................................... 3 BAB II LANDASAN TEORI ....................................................................................... 6 2.1 Waktu Setup ....................................................................................................... 6 2.2 Keuntungan dari Penyederhanaan Prosedur Setup Mesin .................................. 7 2.3 Langkah-Langkah Dasar Prosedur Setup ........................................................... 8 2.4 Konsep SMED .................................................................................................... 9 2.5 Tahapan Metode SMED .................................................................................... 10 2.6 Manfaat Metode SMED .................................................................................... 11 2.7 Rumus SMED.................................................................................................... 16 2.8 Melakukan Pengukuran Waktu ......................................................................... 16 v
2.9 Tingkat Ketelitian, Tingkat Keyakinan dan Pengujian Keseragaman Data ...... 18 2.10 Perhitungan Waktu Siklus ............................................................................... 18 2.11 Cause and Effect Diagram .............................................................................. 19 2.12 Peta Proses Operasi ........................................................................................ 21 2.11.1 Kegunaan Peta Proses Operasi ................................................................. 21 2.11.2 Prinsip-prinsip Pembuatan Peta Proses Operasi (OPC) ............................ 22 2.13 Waste (Pemborosan) ........................................................................................ 22 BAB III METODOLOGI PENELITIAN.................................................................... 25 3.1 Flow Chart Pemecahan Masalah ....................................................................... 25 3.2 Uraian Flowchart Pemecahan Masalah ............................................................. 26 3.2.1 Studi Literatur ............................................................................................. 26 3.2.2 Identifikasi Masalah .................................................................................... 26 3.2.3 Rumusan Masalah ....................................................................................... 26 3.2.4 Pengumpulan Data ...................................................................................... 26 3.2.5 Pengolahan Data ......................................................................................... 27 3.2.6 Analisis ....................................................................................................... 29 3.2.7 Kesimpulan dan saran ................................................................................. 29 BAB IV PENGUMPULAN DAN PENGOLAHAN DATA ...................................... 30 4.1 Pengumpulan Data ............................................................................................ 30 4.1.1 Sejarah Perusahaan ..................................................................................... 30 4.1.2 Visi, Misi, dan Tujuan Perusahaan ............................................................. 32 4.1.3 Jenis Produk yang Diproduksi .................................................................... 33 4.1.4 Struktur Organisasi ..................................................................................... 34 vi
4.1.5 Job Description ........................................................................................... 36 4.1.6 Mesin-Mesin Untuk Produksi Tiang Listrik ............................................... 42 4.1.7 Sistem Penjadwalan Produk........................................................................ 43 4.1.8 Sistem Penjadwalan Produk........................................................................ 44 4.1.9 Perencanaan Kebutuhan Sumber Daya Manusia ........................................ 44 4.1.10 Uraian Kegiatan Setup .............................................................................. 46 4.1.11 Data Waktu Setup Tiang Listrik ............................................................... 47 4.1.13 Waktu Pembuatan Tiang Listrik ............................................................... 49 4.1.14 Jumlah Mesin ............................................................................................ 50 4.2 Pengolahan Data ................................................................................................ 51 4.2.1 Identifikasi Masalah Waktu Setup .............................................................. 51 4.2.2 Uji Kecukupan Data.................................................................................... 54 4.2.3 Uji Keseragaman Data ................................................................................ 55 4.2.4 Waktu Siklus ............................................................................................... 55 4.2.5 Kegiatan Waktu Setup Sebelum Menggunakan SMED ............................. 56 4.2.6 Identifikasi Aktivitas Internal dan Eksternal Setup .................................... 59 4.2.7 Pemisahan Internal dan Eksternal Setup Dengan SMED ........................... 64 4.2.8 Waktu Penyelesaian Tiang Listrik .............................................................. 68 BAB V ANALISIS ..................................................................................................... 69 5.1 Analisis Identifikasi Masalah Waktu Setup ....................................................... 69 5.2 Perbandingan SMED ........................................................................................ 70 5.3 Waktu Penyelesaian Tiang Listrik .................................................................... 72
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BAB VI KESIMPULAN DAN SARAN .................................................................... 73 6.1 Kesimpulan ........................................................................................................ 73 6.2 Saran .................................................................................................................. 73 DAFTAR PUSTAKA ................................................................................................. 75 LAMPIRAN ................................................................................................................ 77
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DAFTAR GAMBAR Gambar 2.1 Diagram Sebab Akibat ............................................................................ 21 Gambar 3.1 Flow Chart Kegiatan Penelitian .............................................................. 25 Gambar 4.1 Bagan Organisasi PT. PLN (PERSERO) ................................................ 35 Gambar 4.2 Mesin Press ............................................................................................. 42 Gambar 4.3 Diagram Sebab Akibat ............................................................................ 51
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DAFTAR TABEL Tabel 2.1 Langkah-langkah Proses Setup ..................................................................... 8 Tabel 2.2 Waktu setup rata-rata .................................................................................. 16 Tabel 4.1 Jumlah Karyawan ........................................................................................ 44 Tabel 4.2 Penguraian kegatan waktu setup sebelum menggunakan SMED ............... 46 Tabel 4.3 Data waktu setup bulan Januari-Juni 2013 ................................................. 47 Tabel 4.4 Data waktu setup bulan Januari-Juni 2013 (lanjutan) ................................. 48 Tabel 4.5 Total waktu pembuatan tiang listrik ........................................................... 49 Tabel 4.6 Jumlah mesin yang di gunakan dalam proses pembuatan tiang listrik ....... 50 Tabel 4.7 Poin Kuesioner ............................................................................................ 52 Tabel 4.8 Rekapitulasi Penyebab Terjadinya Keterlambatan waktu setup ................. 52 Tabel 4.9 Kegiatan waktu setup sebelum menggunakan SMED ................................ 56 Tabel 4.10 Kegiatan waktu setup sebelum menggunakan SMED (Lanjutan) ............ 57 Tabel 4.11 Rekap waktu setup sebelum SMED .......................................................... 57 Tabel 4.12 Rekap waktu setup dari masing-masing mesin sebelum SMED .............. 58 Tabel 4.13 Rata-rata waktu setup pembuatan tiang listrik sebelum SMED ............... 58 Tabel 4.14 Identifikasi pemisahan aktivitas internal dan eksternal setup ................... 63 Tabel 4.15 Pemisahan internal dan eksternal setup .................................................... 64 Tabel 4.16 Pemisahan internal dan eksternal setup (Lanjutan)................................... 65 Tabel 4.17 Rekap waktu setup internal dan eksternal dengan SMED ........................ 65 Tabel 4.18 Waktu setup total dari setiap mesin dengan SMED .................................. 66 Tabel 4.19 Waktu setup rata-rata dengan SMED........................................................ 67 Tabel 4.20 Perbandingan waktu setup sebelum dan sesudah SMED.......................... 67 Tabel 5.1 Waktu setup rata-rata sebelum menggunakan SMED ................................ 71 Tabel 5.2 Waktu setup rata-rata dengan SMED.......................................................... 71 Tabel 5.3 Perbandingan waktu setup sebelum dan sesudah SMED............................ 71
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DAFTAR LAMPIRAN Lampiran 1 Lambang Dalam Peta Proses Operasi ...................................................... 78 Lampiran 2 Peta Proses Operasi Pembuatan Tiang Listrik ......................................... 80 Lampiran 3 Rekap Data Waktu Proses Operasi .......................................................... 81 Lampiran 4 Uji Kecukupan Data Proses Operasi Tiang Listrik ................................. 85 Lampiran 5 Uji Keseragaman Data Proses Operasi Tiang Listrik .............................. 89 Lampiran 6 Data Waktu Setup .................................................................................... 93 Lampiran 7 Data Produksi Tiang Listrik .................................................................. 117 Lampiran 8 Foto Tempat Produksi Tiang Listrik ..................................................... 121 Lampiran 9 Kuesioner Persentase Keterlambatan Waktu Setup ............................... 122
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