KAJIAN TOTAL PRODUCTIVE MAINTENANCE PADA PEMBANGKIT LISTRIK TENAGA GAS DAN UAP BLOK I ST 1.0 SICANANG BELAWAN DENGAN METODE OVERALL EQUIPMENT EFFECTIVENESS
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi Syarat Memperoleh Gelar Sarjana Teknik
HASBER F. H. SITANGGANG NIM. 110421011
PROGRAM PENDIDIKAN SARJANA EKSTENSI DEPARTEMEN TEKNIK MESIN FAKULTAS TEKNIK UNIVERSITAS SUMATERA UTARA MEDAN 2015
ABSTRAK
PT. PLN (Persero) merupakan perusahaan yang bergerak dalam bidang penghasil energi listrik yang tidak terlepas dari masalah efektivitas peralatan dan mesin yang diakibatkan oleh six big losses. Dampak dari masalah tersebut akan mengganggu mesin bekerja sesuai dengan hasil yang seharusnya dicapai. Oleh karena itu perlu adanya perhatian yang khusus mengenai pemeliharaan dan perawatan terhadap mesin dengan tujuan mesin dapat melakukan proses produksi dengan lebih lama dan menghasilkan keuntungan yang diharapkan.Overall Equipment Effectiveness (OEE) adalah salah satu alat untuk meningkatkan tingkat efektifan pemanfaatan mesin dan peralatan. OEE merupakan sebagai salah satu aplikasi program dari Total Productive Maintenance (TPM). Total Productive Maintenance merupakan suatu prinsip manajemen untuk meningkatkan produktivitas dan efisiensi produksi perusahaan dengan menggunakan mesin secara efektif. Penelitian ini mengukur nilai OEE satu lini produksi dari energi listrik di PT. PLN (Persero) Sicanang Belawan dalam satu periode, dilanjutkan dengan menganalisa nilai dengan menggunakan analisa pareto dari hasil yang diperoleh oleh akar penyebab OEE tersebut.Kesimpulannya bahwa nilai hasil analisa yang diperoleh rata-rata tidak melampaui nilai standar dari OEE<85 %, oleh karena mesin masih dalam keadaan kurang baik..Faktor yang mungkin akan mengalami drop secara cepat diprediksi adalah minor stoppages loss2275,49 jam,yield/scrap losses 2003,4 jam, reduce speed loss 2237,24 jam, breakdown losses 399,56 jam dan synkron and adjustment losses 399,56 jamakibat yang mungkin tidak begitu berdampak dalam waktu yang cepat, tetapi akan segera menyerang mesin jika perawatan tidak dilakukan secara berkesinambungan dan teratur.
Kata kunci : Overall Equipment Effectiveness (OEE), Total Productive Maintenance, dan Six Big Losses.
ABSTRACT
PT. PLN (Persero) is a company engaged in the producer of electrical energy which is inseparable from the effectiveness of machinery and equipment problems caused
by the six big losses. The impact of these problems will
interfere with the machine work in accordance with the results that should be achieved. Hence the need for special attention regarding the maintenance and care of the machine with the purpose of the machine is capable of committing a longer production process and generate a profit as expected.Overall Equipment Effectiveness (OEE) is one of the tools to enhance the effectiveness of the utilization rate of machinery and equipment. OEE is as one of the application programs of Total Productive Maintenance (TPM). Total Productive Maintenance is a principle of management to improve productivity and efficiency of the production company to use the machine effectively. This study measures the value of OEE which one production line of electric energy in PT. PLN (Persero) Sicanang Belawan in the period, followed by analyzing the value of using Pareto analysis of the results obtained by the root causes of the OEE.The conclusion that the value of the analysis results obtained on average exceeded the standard value of OEE< 85%, because the engine is still in good condition.Factors that may experience rapid drop predicted loss is minor stoppages 2275.49 hours, yield/scrap losses 2003,4 hours, reduce speed loss 2237.24 hours, breakdown losses 399,56 hours, and synkron and adjustment losses 399,56 hours as a result of which may not have an impact in a short time, but will immediately attack the machine if no have treat of maintenance as continously and directly.
Keywords: Overall Equipment Maintenance, and Six Big Losses.
Effectiveness
DAFTAR ISI
(OEE),
Total
Productive
KATA PENGANTAR ...................................................................................... i ABSTRACT ...................................................................................................... iii ABSTRACT ...................................................................................................... iv DAFTAR ISI ..................................................................................................... v DAFTAR GAMBAR ....................................... .................................................viii DAFTAR TABEL ..... ….................................................................................... ix DAFTAR SIMBOL .................................................................. ......................... x BAB I PENDAHULUAN ............................................................................... 1 1.1.Latar Belakang ............................................................................... 1 1.2.Permasalahan ................................................................................. 2 1.3.Rumusan Masalah .......................................................................... 2 1.4.Batasan Masalah ............................................................................ 2 1.5.Asumsi-asumsi ............................................................................... 3 1.6.Tujuan Penelitian ............................................................................ 3 1.6.1. Tujuan Umum....................................................................... 3 1.6.2. Tujuan Khusus ...................................................................... 3 1.7.Manfaat Penulisan ........................................................................... 3 1.8.Metode Penelitian ........................................................................... 4 1.9.Sistematika Penelitian ..................................................................... 4
BAB II TINJAUAN PUSTAKA .................................................................... 6 2.1. Pembangkit Listrik Tenaga Uap dan Gas ..................................... 6 2.1.1. Prinsip Kerja PLTGU ......................................................... 7 2.1.2. Siklus PLTGU...................................................................... 8 2.1.3. Bagian Utama PLTGU......................................................... 9 2.1.3.1. PLTG (Pembangkit Listrik Tenaga Gas)................. 9 2.1.3.2. HRSG (Heat Recovery Steam Generator) ............... 10 2.1.3.3. Turbin Uap (Steam Turbine) ................................... 10 2.2. Pemeliharaan (Maintenance) PLTGU ........................................... 11 2.3. PLTGU ST 1.0 ............................................................................... 12 2.4. Pengertian Pemeliharaan (Maintenace) ........................................ 13
2.4.1. Tujuan Maintenance ............................................................ 15 2.4.2. Jenis-jenis Maintenance ....................................................... 15 2.4.3. Total Productive Maintenance............................................. 20 2.4.3.1. Pengertian Total Productive Maintenance .............. 21 2.4.4. Tujuan Total Productive Maintenance ................................ 25 2.4.5. Manfaat Total Productive Maintenance .............................. 26 2.4.5.1. Penurunan Mesin (Downtime) ................................. 27 2.4.5.2. Kerugian Akibat Penurunan Kecepatan (Speed Losses) ......................................................... 28 2.4.5.3. Kerugian Karena Terjadinya cacat (Defects) .......... 28 2.5. Overall Equipment Effectiveness ................................................... 29 2.5.1. Kesediaan Waktu Mesin (Availability) ............................... 30 2.5.2. Efisiensi Performansi (Performance Efficiency) ................ 31 2.5.3. Perbandingan Kualitas Produk yang Dihasilkan (Rate of Quality Product) ................................................... 32 2.5.4. Diagram Pareto .................................................................... 32 2.5.5. Diagram Sebab-Akibat (Cause and Effect Diagram) .......... 34
BAB III METODOLOGI PENELITIAN ..................................................... 35 3.1. Metode Kuantitatif Eksperimen .................................................... 35 3.2. Lokasi Penelitian ........................................................................... 35 3.3. Rancangan Penelitian ..................................................................... 35 3.4. Sumber dan Jenis Data .................................................................. 36 3.5. Variabel Penelitian ......................................................................... 36 3.6. Instrumen Penelitian ...................................................................... 36 3.7. Pelaksanaan Penelitian ................................................................... 36 3.8. Sistematis Penelitian ...................................................................... 37 3.9. Analisa Data dan Pemecahan Masalah .......................................... 39 3.10. Diagram Alir Penelitian ............................................................... 40 3.11. Pengumpulan Data ....................................................................... 40 3.11.1. Data waktu Planned/ Pemeliharaan ST 1.0 ....................... 41 3.11.2. Data waktu Operation ST 1.0 ............................................ 42
3.11.3. Data Waktu Setup ST 1.0................................................... 43 3.11.4. Data Produksi ST 1.0 ......................................................... 44
BAB IV PENGOLAHAN DAN ANALISA DATA ...................................... 46 4.1. Pengolaha Data ............................................................................. 46 4.1.1. Perhitungan Availability (AV) ............................................. 46 4.1.2. Perhitungan Performancy Efficiency ................................... 48 4.1.3. Perhitungan Rate of Quality Product (RQP) ...................... 49 4.1.4. Perhitungan Overall Equipment Effectivenes (OEE) ........... 50 4.1.5. Perhitungan Six Big Losses .................................................. 51 4.1.5.1. Downtime Losses ..................................................... 51 4.1.5.2. Speed Losses ............................................................ 54 4.1.5.3. Defect Losses ........................................................... 57 4.2. Analisa Perhitungan ....................................................................... 59 4.2.1. Analisis Perhitungan Overall Equipment Effectiveness (OEE) ................................................................................... 59 4.2.2. Analisa Perhitungan Six Big Losses .................................... 61 4.2.3. Analisa Diagram Sebab-Akibat .......................................... 62 4.2.4. Penyelesaian Masalah .......................................................... 67 4.2.4.1. Penyelesaian Masalah Six Big Losses ..................... 67 4.2.4.2. Penerapan Total Productive Maintenance .............. 68
BAB V KESIMPULAN DAN SARAN .......................................................... 70 5.1. Kesimpulan ................................................................................... 70 5.2. Saran ............................................................................................. 70
DAFTAR PUSTAKA LAMPIRAN
DAFTAR GAMBAR
Gambar 2.1
Prinsip Kerja PLTGU .................................................................. 7
Gambar 2.2
Siklus Kombinasi ........................................................................ 8
Gambar 2.3
Siklus Bryton, Siklus Rankine, Siklus Kombinasi ...................... 9
Gambar 2.4
Komponen Penyusun PLTG ........................................................ 9
Gambar 2.5
Heat Recovery Steam Generator ................................................. 10
Gambar 2.6
Turbin Uap................................................................................... 10
Gambar 2.7
Pillar-pilar TPM........................................................................... 23
Gambar 2.8
Diagram Pareto ............................................................................ 33
Gambar 2.9
Diagram Sebab Akibat ................................................................ 34
Gambar 3.1
Diagram Alir Penelitian ............................................................... 40
Gambar 4.1
Grafik Persentase OEE ................................................................ 60
Gambar 4.2
Diagram Total Time Big Six Losses ............................................ 62
Gambar 4.3
Diagram Sebab Akibat Idling speed and Minor stopagges Losses .......................................................................................... 63
Gambar 4.4
Diagram Sebab Akibat Yield /Scrap Losses ................................ 63
Gambar 4.5
Diagram Sebab Akibat Reduce Speed Loss ................................. 64
DAFTAR TABEL
Tabel 2.1
Jadual Pemeliharaan Mesin Turbin Gas dan Uap ST 1.0 ............ 13
Tabel 3.1
Data Pemeliharaan ST 1.0Periode Mei 2014- Mei 2015............. 41
Tabel 3.2
Data Waktu Operation ST 1.0Periode Mei 2014- Mei 2015 ....... 42
Tabel 3.3
Data Waktu SynkronST 1.0Periode Mei 2014- Mei 2015 .......... 43
Tabel 3.4
Data Produksi ST 1.0 Periode Mei 2014 – Mei 2015................. 44
Tabel 4.1
World Class of OEE .................................................................... 46
Tabel 4.2
Availabiliy ST 1.0 Periode Mei 2014 – Mei 2015 ....................... 47
Tabel 4.3
Performance Efficiency ST 1.0 Periode Mei 2014-Juni 2015 .... 48
Tabel 4.4
Rate of Quality Product Turbin Gas dan Uap Mei 2014 – Mei 2015...................................................................................... 49
Tabel 4.5
Overall Equipment Effectiveness Turbin Gas dan Uap ST 1.0 Periode Mei 2014 – Mei 2015 ........................................ 51
Tabel 4.6
Breakdown Loss ST 1.0 Periode Mei 2014 –Mei 2015 ............... 52
Tabel 4.7
Setup and Adjustment ST 1.0 Periode Mei 2014 – Mei 2015...................................................................................... 53
Tabel 4.8
Idling and Minor Stoppages Loss ST 1.0 Juli 2014 – Mei 2015...................................................................................... 55
Tabel 4.9
Reduce Speed Loss ST 1.0 Periode Mei 2014 – Mei 2015 .......... 56
Tabel 4.10
Rework Loss ST 1.0 Periode Mei 2014 – Mei 2015 .................... 57
Tabel 4.11
Yield/Scrap Loss ST 1.0 Periode Mei 2014 – Mei 2015 ............ 59
Tabel 4.12.
Persentase OEE Setiap Periodenya ............................................. 60
Tabel 4.13.
Total Time Six Big Losses Turbin Gas dan Uap ST 1.0 Periode Mei 2014 – Mei 2015 .................................................................. 61
DAFTAR SIMBOL
Simbol AV EF IMS OEE PE RQP RS RL SA YS
Nama Availability Breakdowntime Downtime Equipment Failure (Breakdowns) Ideal Cycle Time Idling and Minor Stoppages Loss Loading Time Net Operating Non Productive Time Operating Cycle Time Operation Time Overall Equipment Effectivenes (OEE) Performance Efficiency Planned Down Time Product Used Rate Of Quality Product Reduce Speed Rework Loss Result Processed Set up Setup and Adjustment Total Actual Press Hours Total Availability Time Total Processed Amount Yield/Scrap Loss
BAB I PENDAHULUAN
Satuan % Jam Jam Jam Jam/Kwh Jam Jam Jam Jam Jam Jam % % Jam Kwh % % % KWh Jam Jam KWh Jam KWh Jam
