LAPORAN TUGAS AKHIR
PERHITUNGAN DAN ANALISA NILAI OVERALL EQUIPMENT EFFECTIVENESS (OEE) PADA PROSES UNIT BURNING (Studi Kasus PT. Indocement Tunggal Prakarsa,Tbk)
Diajukan Guna Melengkapi Sebagai Syarat Dalam Mencapai Gelar Sarjana Strata Satu (S1)
Disusun Oleh : Nama Nim Program Studi
: Novian : 41610010034 : Teknik Industri
PROGRAM STUDI TEKNIK INDUSTRI FAKULTAS TEKNIK UNIVERSITAS MERCU BUANA JAKARTA 2014
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KATA PENGANTAR Puji syukur kehadirat Tuhan Yang Maha Esa karena atas berkat dan rahmatNya, penulis dapat menyelesaikan tugas akhir ini dalam rangka memenuhi salahsatupersyaratanuntukmenyelesaikanpendidikan Teknik Industri. Dalam penyusunan tugas akhirini penulis mengalami banyak kendala dan keterbatasan, akan tetapi dengan segala bantuan, dorongan, dan semangat dari berbagai pihak penulis dapat menyelesaikan tugas akhirini. Untuk itu, pada kesempatan ini dengan segenap kerendahan hati penulis mengucapkan terima kasih kepada : 1. Bapak Dr. Ir. Dana Santoso, M.Eng,Sc,Ph.D selaku dekan dari Fakultas TeknikUniversitas Mercu Buana dan selaku pembimbing yang mendukung dan memberi bantuan kepada penulis dalam penyusunan tugas akhir ini. 2. Bapak Ir. Muhammad Kholil, MT selaku Ketua Program Studi Teknik Industri Universitas Mercu Buana. 3. Para dosen dan staf pengajar yang telah membantu memperluas pengetahuan penulis dalam menempuh studi. 4. Ayah, Ibu, kakak-kakak dan keluarga tercinta yang senantiasa selalu mendoakan, mendukung, dan memberikan dukungan moril serta material kepada penulis. 5. Segenap Direksi, Plant 1-2 Manager dan Engeenering Manager serta seluruh staf PT. Indocemet Tunggal Prakarsa, Tbk yang telah mengijinkan penulis melaksanakan kerja praktek di PT. Indocement Tunggal Prakarsa, Tbk. 6. Agus Raif dan Puspita Sari Ramadini selaku teman yang selama ini dengan sabar mendampingi penulis, memberikan semangat, doa, motivasi, dan pengertiannya. Serta teman-teman seperjuangan di Teknik Industri Universitas Mercu Buana khususnya angkatan 2010. 7. Pihak-pihak lain yang langsung maupun tidak langsung membantu yang tidak sempat penulis sebutkan satu-persatu dalam laporan karya akhir ini. vi
Penulis menyadari bahwa masih banyak sekali kekurangan yang terdapat pada tugas akhirini. Oleh karena itu, kritik dan saran dari pembaca sangatlah dibutuhkan untuk kemajuan dan kesempurnaan selanjutnya bagi penulis. Penulis berharap laporan kerja praktekini dapat memberikan manfaat bagi pengembangan ilmu, pihak-pihak yang membutuhkan serta dapat menjadi referensi bagi penulis tugas akhirlainnya.
Jakarta, April 2014
Penulis
(Novian)
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DAFTAR ISI
HALAMAN JUDUL...........................................................................................i LEMBAR PERNYATAAN ................................................................................ii LEMBAR PENGESAHAN ................................................................................iii ABSTRAK ..........................................................................................................iv ABSTRACT ........................................................................................................v KATA PENGANTAR ........................................................................................vi DAFTAR ISI .......................................................................................................viii DAFTAR TABEL ...............................................................................................xi DAFTAR GAMBAR ..........................................................................................xii
BAB I PENDAHULUAN ..................................................................................1 1.1 Latar Belakang Masalah ..................................................................1 1.2 Rumusan Masalah ...........................................................................4 1.3 Batasan Masalah ..............................................................................4 1.4 Tujuan Penelitian.............................................................................5 1.5 Metodologi Penelitian .....................................................................6 1.6 Sistematika Penulisan ......................................................................6
BAB II LANDASAN TEORI ...........................................................................8 2.1 Pengertian Maintenance ....................................................................8 2.1.1 Maintenance Performance Measurement .................................9 2.1.2 Tujuan Maintenance ..................................................................10 2.1.3 Fungsi Maintenance ...................................................................11 2.1.4 Jenis-Jenis Maintenance ............................................................12 2.1.4.1 Pemeliharaan Terencana (Planned Maintenance) ..........12 2.1.4.2 Pemeliharaan Tak Terencana .........................................16 2.2 Total Productive Maintenance (TPM) ..............................................17 2.2.1 Tujuan dan Sasaran TPM .........................................................19 viii
2.2.2 Pilar-Pilar TPM ........................................................................22 2.2.3 Dasar Pelaksanaan TPM...........................................................24 2.3 Overall Equipment Effectiveness (OEE) ...........................................25 2.3.1 Tujuan Implementasi OEE .........................................................27 2.3.2 Pengukuran Nilai OEE ..............................................................28 2.4 Diagram Sebab-Akibat (Ishikawa) ....................................................32
BAB III METODOLOGI PENELITIAN .......................................................34 3.1 Tahapan Pelaksanaan Penelitian .......................................................34 3.2 Identifikasi Perumusan Masalah .......................................................35 3.3 Ruang Lingkup Penelitian .................................................................39 3.4 Metode Penelitian ..............................................................................40 3.4.1 Metode Pengumpulan Data .....................................................40 3.4.2 Metode Pengolahan Data ........................................................40 3.5 Tahap Analisa dan Pemecahan Masalah ...........................................41 3.6 Tahap Kesimpulan dan Saran ............................................................42
BAB IV PENGUMPULAN DAN PENGELOLAAN DATA .........................43 4.1 Pengumpulan Data ...........................................................................43 4.1.1 Profil PT. Indocement Tunggal Prakarsa, Tbk ........................43 4.1.2 Visi, Misi, dan Motto Perusahaan ...........................................46 4.1.3 Lokasi Pabrik...........................................................................46 4.1.4 Produk Semen di PT. ITP .................................................... 47 4.1.5 Proses Produksi Semen di PT. ITP..........................................49 4.2 Macam-macam Mesin dibagian Unit Burning/Klin .........................59 4.3 Jam Kerja Karyawan PT. ITP ..........................................................50 4.4 Pengendalian Produksi .....................................................................65 4.4.1 Pengendalian Bahan Baku .......................................................66 4.4.2 Pengendalian Proses Produksi .................................................67 4.4.3 Pengendalian Produk Jadi .......................................................67 4.4.4 Pengendalian Mutu .............................................................. 68 ix
4.5 Manajemen Rantai Pemasok ............................................................69 4.6 Manajemen Perawatan Fasilitas .......................................................70 4.6.1 Pelaksanaan Autonomous Maintenance ..................................72 4.6.2 Implementasi Penggunaan Dokumentasi ................................74 4.7 Pengolahan Data ...............................................................................83 4.7.1 Pengukuran Nilai Availability Rate ...........................................85 4.7.2 Pengukuran Nilai Performance Rate.......................................86 4.7.3 Pengukuran Nilai Quality Rate ...............................................89 4.7.4 Pengukuran Nilai OEE ......................................................... 91 4.7.4 Pengukuran Nilai Losses ...................................................... 92
BAB V ANALISA HASIL ................................................................................99 5.1 Analisa Hasil .....................................................................................99 5.1.1 Analisa Nilai Availability Rate ..................................................100 5.1.2 Analisa Nilai Performance Rate ...............................................101 5.1.3 Analisa Nilai Quality Rate ........................................................102 5.1.4 Analisa Pengukuran Nilai OEE .................................................104 5.1.5 Analisa Losses .............................................................................105 5.2 Analisa Permasalahan Menggunakan Diagram Sebab-Akibat ..........107 5.3 Evaluasi atau Usulan Pemecahan Masalah .......................................110 5.4 Rekomendasi dalam penerapan TPM ................................................112
BAB VI KESIMPULAN DAN SARAN...........................................................120 6.1 Kesimpulan........................................................................................120 6.2 Saran ..................................................................................................122 6.2.1 Saran bagi Perusahaan ..............................................................122 6.2.2 Saran bagi penelitian lebih lanjut .............................................123
DAFTAR PUSTAKA ........................................................................................124 LAMPIRAN .......................................................................................................126
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DAFTAR TABEL Tabel 4.1 Jam Kerja Normal Departemen Mining dan Packing...................... 64 Tabel 4.2 Jam KerjaNormal Selain Departemen Mining dan Packing ............ 64 Tabel 4.3 JamKerja Shift Mechanic, Electric, Production dan QC Dept ........ 65 Tabel 4.4 Jam Kerja Shift Paper Bag Departement ........................................ 65 Tabel 4.5 Data Produksi Mesin Rotary Kiln .......................................................84 Tabel 4.6 Data Waktu Operasi dan Delay Mesin Rotary Kiln ............................84 Tabel 4.7 Perhitungan Availability Rate .............................................................86 Tabel 4.8 Perhitungan Jam Kerja Efektif dan Waktu Siklus ..............................88 Tabel 4.9 Perhitungan Performance Rate............................................................89 Tabel 4.10 Perhitungan Quality Rate ..................................................................90 Tabel 4.11 Perhitungan Nilai OEE......................................................................92 Tabel 4.12 Perhitungan Equpiment Failur Losses ..............................................93 Tabel 4.13 Perhitungan Setup & adjustment Losses ...........................................94 Tabel 4.14 Perhitungan Defect Losses ................................................................95 Tabel 4.15 Perhitungan Reduced Speed Losses ..................................................96 Tabel 4.16 Perhitungan Target Produksi .............................................................97 Tabel 4.17 Perhitungan Idle & Minor Stoppages................................................98 Tabel 5.1 Nilai Ideal Overall Equipment Effectiveness (OEE) ......................... 99 Tabel 5.2 Nilai Availability Rate Mesin Rotary Kiln ....................................... 100 Tabel 5.3 Nilai Performance Rate Mesin Rotary Kiln ..................................... 101 Tabel 5.4 Nilai Quality Rate Mesin Rotary Kiln ............................................. 102 Tabel 5.5 Nilai OEE Mesin Rotary Kiln .............................................................103 Tabel 5.6 Nilai Losses Mesin Rotary Kiln ..........................................................104
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DAFTAR GAMBAR Gambar 2.1 Jenis-Jenis Pemeliharaan .................................................................16 Gambar 2.2 Pillars Of TPM ................................................................................22 Gambar 2.3 Tahap Perhitungan OEE ..................................................................29 Gambar 2.4 Diagram Sebab Akibat (Fishbone) ..................................................33 Gambar 3.1 Flowchart Penelitian .......................................................................36 Gambar 3.2 Diagram Proses Produksi ................................................................37 Gambar 4.1 Struktur Organisasi Perusahaan ......................................................45 Gambar 4.2 Ordinary Portland Cement (OPC) ..................................................47 Gambar 4.3 Portland Composite Cement (PCC) ................................................47 Gambar 4.4 Oil Well Cement (OWC) ..................................................................47 Gambar 4.5 White Cement ..................................................................................48 Gambar 4.6 White Mortar TR30 .........................................................................48 Gambar 4.7 Proses Produksi Semen PT. ITP ......................................................59 Gambar 4.8 Mesin Suspension Preheater (SP) ...................................................60 Gambar 4.9 Mesin Rotary Kiln ...........................................................................61 Gambar 4.10 Mesin Air Quenching Cooler (grate cooler) .................................62 Gambar 4.11 Mesin Clinker Silo .........................................................................63 Gambar 4.12 Rantai Pasok ..................................................................................70 Gambar 4.13 Pergantian Shim Plate ...................................................................74 Gambar 4.14 Kiln Shell Red Spot ........................................................................76 Gambar 4.15 Penggantian Metal Bearing ...........................................................77 Gambar 4.16 Tyre................................................................................................79 Gambar 4.17 Kerusakan Grate Cooler ...............................................................79 Gambar 4.18 Kerusakan Kiln Burner .................................................................80 Gambar 4.19 Penggantian Bata pada Unit Rotary Kiln ......................................81 Gambar 4.20 Penggantian Oli pada Mesin Kiln Maindrive ..............................82 Gambar 5.1 Diagram Nilai Availability Rate ....................................................100 Gambar 5.2 Diagram Nilai Performance Rate ..................................................102 Gambar 5.3 Diagram Nilai Quality Rate...........................................................103 xii
Gambar 5.4 Diagram Overall Equipment Effectiveness (OEE) ........................105 Gambar 5.5 Diagram Sebab Akibat (Fishbone) ................................................108
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