IMPLEMENTASI TOTAL PRODUCTIVE MAINTENANCE DENGAN METODE OVERAL EQUIPMENT EFECTIVENESS (OEE) UNTUK MENENTUKAN MAINTENANCE STRATEGY PADA MESIN DIGESTER PLANT (STUDY KASUS PT. TOBA PULP LESTARI, Tbk)
SKRIPSI Skripsi Yang Diajukan Untuk Melengkapi Syarat Memperoleh Gelar Sarjana Teknik
Oleh : JUNA GELISMAN EDWARD GINTING 110401046
DEPARTEMEN TEKNIK MESIN FAKULTAS TEKNIK UNIVERSITAS SUMATERA UTARA MEDAN 2016
Universitas Sumatera Utara
ABSTRACT Penelitian ini menganalisis tentang implementasi Total Productive maintenace (TPM) pada mesin Digester dengan menggunakan metode Overall Equipment Efectiveness (OEE). Total Productive Maintenance (TPM)adalah untuk meningkatkan produktivitas pada perlengkapan dan peralatan produksi dengan investasi perawatan yang seperlunya sehingga mencegah terjadi 6 kerugian besar (Six Big Losses). Six Big Losses yang menyebabkan kerugian tersebut diantaranya adalah: Kerugian karena kerusakan peralatan (Breakdown Losses), kerugian karena pemasangan peralatan (Set-up and Adjustment losses), kerugian karena beroperasi tanpa beban maupun berhenti sesaat (Idling and minor stoppages), kerugian karena penurunan kecepatan produksi (Reduced Speed Losses),kerugian karena cacat produk dalam proses (Rework Losses), kerugian karena hasil rendah (Yield/Scrap losses). Berdasarkan hasil perhitungan nilai OEE di mesin Digester selama bulan Juni 2015 - Mei 2015 di peroleh nilai availability = 97.6 % memenuhi standar JIPM sebesar 90%, performance efesiensi = 95.22% memenuhi standar JIPM sebesar 95%, quality of rate = 97.00% kondisi ini tidak memenuhi standar JIPM sebesar 99% , dan hasil nilai OEE = 90.20% produksi dianggap kelas dunia. Skor ini merupakan skor yang cocok untuk dijadikan goal jangka panjang. Faktor yang memiliki persentase terbesar dari factor six big losses adalah idling and minor losses sebesar 50.98%, reduce speed losses sebesar 23.59%, yield/scrap losses 14.49% set up and adjustment sebesar 10.20%, Breakdown losses sebesar 0.78%. dan untuk meningkatkan nilai OEE penggantian spareparts genuie digunakan untuk menganti spareparts yang rusak.
Kata kunci : Total Productive Maintenance (TPM), Overall Equipment Efectiveness, Six Big Losses, Digester plant.
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ABSTRACT This study analyzed the implementation of Total Productive maintenace (TPM) on the machine Digester using Efectiveness Overall Equipment (OEE). Total Productive Maintenance (TPM) is to increase the productivity of the equipment and production equipment with an investment of treatments as necessary to prevent major losses occurred 6 (Six Big Losses). Six Big Losses are causing these losses are: Losses due to damage to the equipment (Breakdown Losses), losses due to the installation of equipment (Set-up and Adjustment losses), losses due to operate without load or paused (Idling and minor stoppages), losses due to the decline production speed (Speed Reduced losses), losses due to product defects in the process (Rework losses), the losses due to the low yield (Yield / Scrap losses).Based on the results of the calculation of OEE values in the machine Digester during the month of June 2015 - May 2015 obtained availability value = 97.6% meet the standard JIPM by 90%, performance efficiency = 95.22% meet the standard JIPM by 95%, quality of rate = 97.00% this condition is not JIPM meet the standards of 99%, and the yield value of OEE = 90.20% is considered a world-class production. This score is a score that is suitable to serve as a long-term goal. The factor that has the greatest percentage of factor six big losses are idling and minor losses amounted to 50.98%, reduce speed losses of 23:59%, yield / scrap losses 14:49% set up and adjustment of 10:20%, Breakdown losses amounted to 0.78%. and to increase the value of OEE replacement of genuie spareparts are used to replace the damaged spare parts.
Keywords: Total Productive Maintenance (TPM), Overall Equipment Efectiveness, Six Big Losses, Digester plant.
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KATA PENGANTAR Puji dan syukur penulis panjatkan kepada Tuhan Yang Maha Esa atas berkatberkatnya yang melimpah dan penyertaannya penulis dapat menyelesaikan skripsi ini dengan baik tepat pada waktunya. Skripsi ini adalah salah satu syarat untuk memperoleh gelar sarjana teknik di Departemen Teknik Mesin, Fakultas Teknik, Universitas Sumatera Utara. Adapun judul skripsi yang dipilih, diambil dari matakuliah Total Productive Maintenance, yaitu: ”IMPLEMENTASI TOTAL PRODUCTIVE MAINTENANCE DENGAN METODE OVERAL EQUIPMENT EFECTIVENESS (OEE) UNTUK MENENTUKAN MAINTENANCE STRATEGY PADA MESIN DIGESTER PLANT (STUDY KASUS PT. TOBA PULP LESTARI, Tbk)”Dalampenulisan skripsi ini, penulis telah berupaya dengan segala kemampuan pembahasan dan penyajian, baik dengan disiplin ilmu yang diperoleh dari perkuliahan, menggunakan literature, serta bimbingan dan arahan dari Bapak Ir. Alfian Hamsi, M.Sc selaku Dosen Pembimbing Skripsi. Selesainyaskripsiinitidakluputdaridoa,
dukungan,
dorongan,
danbantuandariberbagaipihak. Olehkarenaitudenganketulusandankerendahanhatipenulisinginmengucapkanterimakasih yang sebesar-besarnya kepada : 1. Kedua orang tua tercinta, Ayahanda M. Ginting dan Ibunda S.br Bangun, Kakak dan Adik tersayang (Ernita br Ginting, Nurmala br Ginting, Geltri Gelori br Ginting, Analisa br Ginting, Lois Ginting, dan Enima br Ginting) atas doa, kasih sayang, pengorbanan, tangung jawab yang selalu menyertai penulis, dan memberikan penulis semangat yang luar biasa sehingga penulis dapat menyelesaikan skripsi ini. 2. Bapak Ir. Alfian Hamsi, M.Sc selaku Dosen Pembimbing yang telah banyak meluangkan waktunya dan dengan sabar membimbing penulis sehingga skripsi ini dapat terselesaikan dengan baik. 3. Bapak Dr. Ing. Ir. Ikwansyah Isranuri selaku Ketua Jurusan Departemen Teknik Mesin, Fakultas Teknik, Universitas Sumatera Utara. 4. Bapak Ir. Awalluddin Thayab, M.Sc selaku dosen wali penulis. 5. Bapak/Ibu staff pengajar dan pegawai jurusan Departemen Teknik Mesin, Fakultas Teknik, Universitas Sumatera Utara. 6. Bapak Charlie, Paulus Purba, Jimmy Purba, Hotlan Sitorus yang telah membimbing selama melakukan penelitian di PT. Toba Pulp Lestari, Tbk iv
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7. Teman-teman seperjuangan stambuk 2011 khususnya yang menjadi teman diskusi dan menemani penulis selama mengikuti studi dan penyusunan skripsi ini. 8. Keluarga besar Ikatan Mahasiswa Mesin (IMM) Departemen Teknik Mesin, Fakultas Teknik, Universitas Sumatera Utara. 9. Keluarga besar Ikatan Mahasiswa Karo (IMKA PANDE KALIAGA) FT-USU yang telah menampung aspirasi penulis selama berkuliah di Fakultas Teknik, Universitas Sumatera Utara. 10. Kepada Melisa Tarigan atas dukungan, motivasi, semangat dan doa yang telah diberikan selama kuliah dan pengerjaan skripsi. 11. Kepadasahabat saya BasriSembiring, RoysArjunTarigan, Joel BastantaPeranginangin, ImantaSingarimbunatasbantuandandukunganselamakuliahdanpengerjaanskripsi. Penulismenyadarimasihbanyakterdapatkekurangandankelemahandaripenulisanskripsii ni,
olehkarenaitupenulismengharapkankritikdan
saran
yang
bersifatmembangun
agar
kedepannyadapatlebihbaiklagi. Dengandoadanharapandaripenulis, semogatulisaninimemberikanmanfaatkepadapembaca.
Akhir
kata
penulisucapkanbanyakterimakasihdanTuhanmemberkati.
Medan, September 2016 Penulis
Juna Gelisman E. Ginting NIM : 110401046
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DAFTAR ISI
ABSTRAK ...................................................................................................... i KATA PENGANTAR .................................................................................... iii DAFTAR ISI................................................................................................... v DAFTAR GAMBAR ...................................................................................... vii DAFTAR TABEL .......................................................................................... ix BAB I PENDAHULUAN............................................................................... 1 1.1 Latarbelakang ................................................................................. 1 1.2 Perumusan Masalah ....................................................................... 2 1.3 Tujuan Penelitian ........................................................................... 2 1.4 Batasan Masalah Penelitian............................................................ 3 1.5 Metodologi Penulisan .................................................................... 3 1.6 Sistematika Penulisan .................................................................... 4 BAB II TINJAUAN PUSTAKA...................................................................5 2.1 Mesin Digester Plant ..................................................................... 5 2.1.1 Cara Kerja Mesin Digester ..................................................... 7 2.1.2 Komponen-Komponen Utama Mesin Digester ...................... 8 2.1.3 Jenis-jenis Digester ................................................................ 12 2.1.4 Bahan Baku Pengolahan Pulp ................................................ 14 2.2 Pemeliharaan (Maintenance) ......................................................... 16 2.2.1 Pengertian Pemeliharaan (Maintenance)................................ 16 2.2.2 Tujuan Pemeliharaan (Maintenance) ..................................... 18 2.2.3 Jenis-jenis Pemeliharaan (Maintenance) ................................ 20 2.3 Total ProduktiveMaintenance (TPM) ............................................ 27 2.3.1 Pendahuluan ........................................................................... 27 2.3.2 Pengertian Total Produktive Maintenance (TPM) ................ 28 2.3.3 Manfaat dari Total Produktive Maintenance (TPM) ............. 32 2.3.4 Overall Equipment Effectiveness (OEE) ................................ 33 2.3.5 Enam Kerugian Utama (Six Big Losses) ................................ 39 2.3.6 Diagram Sebab Akibat / Fishbone (Ishikawa) Diagram ....... 43 BAB III METODE PENELITIAN.............................................................. 45 3.1 Tempat dan Waktu penelitian ........................................................ 45 vi
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3.1.1 Tempat Penelitian ................................................................... 45 3.1.2 Waktu Penelitian .................................................................... 45 3.2 Rancangan Penelitian ..................................................................... 45 3.3 Objek Penelitian ............................................................................. 45 3.4 Instrumen Penelitian....................................................................... 45 3.5 Pelaksanaan Penelitian ................................................................... 45 3.6 Analisis Data dan Pemecahan Masalah.......................................... 47 BAB IV PENGOLAHAN DAN ANALISA DATA.................................... 49 4.1 Pengumpulan Data ......................................................................... 49 4.1.1 Data waktu downtime ............................................................. 50 4.1.2 Planned Downtime ................................................................. 50 4.1.3 Data Waktu Set Up mesin Digester ........................................ 51 4.1.4 Data Waktu Produksi.............................................................. 52 4.2 Pengolahan Data............................................................................. 54 4.2.1 Perhitungan Avalability .......................................................... 54 4.2.2 Perhitungan Performance Efficiency ...................................... 56 4.2.3 Perhitungan Rate Of Quality Product .................................... 58 4.2.4 Perhitungan Overall Equipment Effectiveness (OEE) ............ 60 4.2.5 Perhitungan Six Big Losses..................................................... 62 4.2.5.1 Downtime Losess .......................................................... 62 4.2.5.2 Speed Losses ................................................................. 65 4.2.5.3 Defect loss .................................................................... 68 4.3 Analisa Perhitungan Data............................................................... 70 4.3.1 Analisa Perhitungan Overall Equipment Effectiveness (OEE) ..................................................................................... 70 4.3.2 Analisis Perhitungan OEE Six Big Losses .............................. 73 4.4 Analisa Diagram Sebab Akibat (Fish Bone) .................................. 74 BAB V KESIMPULAN DAN SARAN…………....................................... 77 5.1 Kesimpulan .................................................................................... 77 5.2 Saran............................................................................................... 77 DAFTAR PUSTAKA ..................................................................................... LAMPIRAN ...................................................................................................
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DAFTAR GAMBAR Gambar 2.1 Mesin digester plant..................................................................... 5 Gambar 2.2 Chip file tempat penampungan chip sebelum dimasak di Digester. ........................................................................................ 6 Gambar 2.3 Aliran Liquor dan uap masuk ke digester. ................................... 7 Gambar 2.4 Mesin Digester ............................................................................. 8 Gambar 2.5 Shuttle Conveyor .......................................................................... 8 Gambar 2.6 Digester ........................................................................................ 9 Gambar 2.7 Telescopic chutes ......................................................................... 9 Gambar 2.8 Liqour heater................................................................................ 10 Gambar 2.9 Pompa sirkulasi ............................................................................ 10 Gambar 2.10 Blow tank.................................................................................... 11 Gambar 2.11 Accumulator tank ....................................................................... 11 Gambar 2.12 Relief Condenser ........................................................................ 12 Gambar 2.13 Perbedaan Batch digester dan Continous digester ..................... 13 Gambar 2.14 Kayu Eucaliptus ......................................................................... 16 Gambar 2.15 Ilustrasi peralatan pemeliharaan................................................. 18 Gambar 2.16 Ilustrasi tujuan perawatan .......................................................... 19 Gambar 2.17 Contoh form perawatan terencana.............................................. 20 Gambar 2.18 ilustrasi kegagalan komponen pada Preventive maintenance ... 21 Gambar 2.19 Ilustrasi corrective maintenance ................................................ 22 Gambar 2.20 Ilustrasi instrument Predictive Maintenance ............................. 23 Gambar 2.21 Pemeliharaan tidak terencana..................................................... 23 Gambar 2.22 Autonomous maintenance .......................................................... 24 Gambar 2.23 Seiichi Nakajima, The father of TPM ........................................ 28 Gambar 2.24 Tujuan TPM ............................................................................... 30 Gambar 2.25 Ilustrasi instrument OEE ............................................................ 34 Gambar 2.26 Enam kerugian utama (six big losses) ........................................ 40 Gambar 2.27 Diagram sebab akibat (fishbone diagram) ................................. 44 Gambar 3.1 Metodelogi penelitian .................................................................. 47 Gambar 3.2 Diagram alir perhitungan Overall Equipment Effectiveness ........ 48 Gambar 4.1 Total Produksi bubur pulp mesin Digester #1 PT. Toba Pulp viii
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Lestari, Tbk bulan Juni 2015 - Mei 2016. .................................. 53 Gambar 4.2 Diagram Availability mesin Digester #1 PT. Toba Pulp Lestari, Tbk ................................................................................. 56 Gambar 4.3 Diagram Performance Efficiency mesin Digester #1 PT. Toba Pulp Lestari, Tbk ........................................................ 58 Gambar 4.4 Diagram Rate of Quality Productmesin Digester #1 PT. Toba Pulp Lestari, Tbk ........................................................ 60 Gambar 4.5 Diagram Overall Equipment Effectiveness (OEE) mesin Digester #1 PT. Toba Pulp Lestari, Tbk ..................................... 62 Gambar 4.6 Perbandingan nilai OEE Mesin Digester #1 periode Juni 2015 – Mei 2016 dengan Standard JIPM (Japan Institute Of Plant Maintenance). .............................................................. 71 Gambar 4.7 Grafik pengaruh persentase Availability rate, Performance efficiency, Rate of QualityProduct, terhadap nilai OEE mesin Digester. ........................................................................... 72 Gambar 4.8 Diagram lingkaran persentase Six Big Losses Mesin Digester #1 ................................................................................. 74 Gambar 4.9 Diagram tulang ikan penyebab frekwensi kebocoran paking yang tinggi .................................................................................. 75
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DAFTAR TABEL Tabel 2.1World class OEE............................................................................... 38 Tabel 4.1Data waktu kerusakan mesin Digester #1......................................... 50 Tabel 4.2 Data waktu pemeliharaan (planned downtime)mesin Digester #1 ...................................................................................... 51 Tabel 4.3 Data waktu Set Up mesin Digester #1 ............................................. 52 Tabel 4.4 Data waktu produksi mesin Digester #1 periode Juni 2015 – Mei 2016.............................................................................. 53 Tabel 4.5 Availability mesin Digester #1pada periode Juni 2015 – Mei 2016.......................................................................................... 55 Tabel 4.6 Nilai Performance Effeciency mesin Digester periode Juni 2015 – Mei 2016.............................................................................. 57 Tabel 4.7 Nilai Rate of Quality Productmesin Digester #1 periode Juni 2015 – Mei 2016.............................................................................. 59 Tabel 4.8 NilaiOverall Equipment Effectiveness (OEE) mesin Digester #1 periode Juni 2015 – Mei 2016. ........................................................ 61 Tabel 4.9 NilaiBreakdown losses mesin Digester #1 periode Juni 2015 – Mei 2016.......................................................................................... 63 Tabel 4.10 NilaiSetup and Adjustment losses mesin Digester #1 periode Juni 2015 – Mei 2016. ..................................................................... 65 Tabel 4.11 Nilai Idling dan Minor pada Mesin Digester #1 periode bulan Juni 2015 - Mei 2016 .................................................................. 66 Tabel 4.12 Hasil Reduce Speed Loss pada Mesin Digester #1 untuk periode Juni 2015 – Mei 2016 ...................................................................... 67 Tabel 4.13 Nilai Yield Lossespada mesin Digester #1 periode Juni 2015 – Mei 2016. .......................................................................... 70 Tabel 4.14 Persentase pencapaian mesin Digester #1 periode Juni 2015 – Mei 2016 ........................................................................... 71 Tabel 4.15 Persentase Faktor Six Big Lossesmesin Digester #1 periode Juni 2015 – Mei 2016.................................................................... 73 Tabel 4.16 Usulan penyelesaian masalah Six Big Losses. ............................... 76
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