PENENTUAN INTERVAL WAKTU PENGGANTIAN KOMPONEN PADA MESIN MULTI BLOCKDENGAN MENGGUNAKAN METODE AGE REPLACEMENT (PT. Malang Indah)
Skripsi DiajukanKepadaUniversitasMuhammadiyah Malang UntukMemenuhi Salah SatuPersyaratanAkademik DalamMenyelesaikan Program SarjanaTeknik
Di SusunOleh :
AMIN DWI NOVIN S. 201110140311084
JurusanTeknikIndustri FakultasTeknik UniversitasMuhammadiyah Malang 2015
LEMBAR PENGESAHAN SKRIPSI PENENTUAN INTERVAL WAKTU PENGGANTIAN KOMPONEN PADA MESIN MULTI BLOCK DENGAN MENGGUNAKAN METODE AGE REPLACEMENT (PT. Malang Indah)
DisusunOleh : AMIN DWI NOVIN S 201110140311084 MenyetujuidanMengesahkan : Malang, 15 Febuari 2016 DosenPembimbing I
DosenPembimbing II
AnnisaKesy, G. ST., MT NIP : 10899090344
Ir. H.M. Kholik, MT NIP : 10893090295 Mengetahui, KetuaJurusanTeknikIndustri
Dr. IlyasMas’udin.,M.Log., S.cm., Ph.D NIP : 10802030364
KATA PEGANTAR Skripsi ini merupakan salah satu persyaratan akademik untuk dapat mencapai gelar kesarjanaan pada Fakultas Teknik Universitas Muhammadiyah Malang. Sehubungan dengan hal tersebut, skripsi ini ditulis untuk mencapai persyaratan tersebut. Skripsi ini berisi tentang penentuan interval waktu penggantian komponen pada mesin multi block dengan metode Age Replacement studi kasus di PT. Malang Indah. Penulis menyadari bahwa tanpa bantuan dan bimbingan dari berbagai pihak, dari masa perkuliahan sampai pada penyusunan skripsi, sangatlah sulit bagi penulis untuk dapat menyelesaikan skripsi ini. Penulis mengucapkan terimakasih kepada semua pihak yang telah membantu dan memberikan dukungan demi terselesaikan skripsi ini. Ucapan terima kasih ini penulis ucapkan kepada : 1. Kedua orang tua 2. Bapak Dr. Ilyas Mas’udin., M.Log., S.cm., Ph.D. selaku Ketua Jurusan Teknik Industri, Fakultas Teknik Universitas Muhammadiyah Malang. 3. Ibu Annisa Kesy G. ST., MT sebagai Dosen Pembimbing Skripsi Pertama. 4. Bapak Ir. H.M. Kholik, MT sebagai Dosen Pembimbing Skripsi Kedua dan sebagai Dosen Wali. 5. Bapak Edy dan seluruh pihak di PT. Malang Indah 6. Seluruh Bapak/Ibu dosen Teknik Indusri Universitas Muhammadiyah Malang. 7. Seluruh Rekan Mahasiswa Teknik Indusri Universitas Muhammadiyah Malang terutama kelas B angkatan 2011 “INGUS FC”. 8. Teman-teman seperjuangan…
Akhir kata, penulis menyadari sepenuhnya bahwa skripsi ini masih jauh dari kesempurnaan, oleh karenanya penulis mohon maaf apabila ditemukan kesalahan dalam sripsi ini. Secara khusus penulis mengharapkan agar skripsi ini dapat memberikan wawasan dan pengetahuan yang baru bagi setiap pembaca. Malang, Febuari 2016
Penulis
DAFTAR ISI Halaman Judul ...................................................................................................................... Lembar Pengesahan Skripsi .................................................................................................. Lembar Asistensi Skripsi ...................................................................................................... Berita Acara Ujian ................................................................................................................ Surat Pernyataan Keaslian ..................................................................................................... Kata Pengantar ....................................................................................................................... i Abstrak ................................................................................................................................... ii Abstract .................................................................................................................................. iii Daftar Isi ............................................................................................................................... iv Daftar Tabel .......................................................................................................................... v Daftar Gambar ...................................................................................................................... vi Daftar Lampiran .................................................................................................................... vii BAB I PENDAHULUAN 1.1. Latar Belakang Penelitian ............................................................................................... 1 1.2. Rumusan Masalah Penelitian ......................................................................................... 2 1.3. Tujuan Penelitian ........................................................................................................... 2 1.4. Manfaat Penelitian ......................................................................................................... 2 1.5. Asumsi ........................................................................................................................... 3 1.6. Batasan Masalah Penelitian ........................................................................................... 3 BAB II LANDASAN TEORI 2.1 Pengertian Perawatan (maintenance) ............................................................................. 4 2.1.1 Fungsi Maintenance ........................................................................................... 5 2.1.2 Keuntungan ........................................................................................................ 5 2.1.3 Jenis-jenis Maintenance ..................................................................................... 6 2.1.3.1. Preventive Maintenance ........................................................................ 6 2.1.3.2. Corrective Maintenance ........................................................................ 8 2.1.3.3. Running Maintenance ........................................................................... 9 2.1.3.4. Predictive Maintenance ........................................................................ 9 2.1.3.5. Breakdown Maintenance ....................................................................... 9 2.1.3.6. Emergency Maintenance ....................................................................... 10
2.1.4. Efisiensi dalam Pemeliharaan ............................................................................ 11 2.1.4.1. Masalah Ekonomi .................................................................................. 12 2.1.4.2. Masalah Teknis ..................................................................................... 13 2.2 Probabilitas .................................................................................................................... 13 2.2.1. Fungsi Padat Probabilitas ................................................................................... 14 2.2.2. Keandalan (Reliability) ...................................................................................... 15 2.2.3. Laju Kerusakan .................................................................................................. 16 2.2.4. Mean Time To Failiure ...................................................................................... 19 2.3 Model Distribusi ............................................................................................................ 20 2.3.1. Distribusi Eksponensial Negatif ......................................................................... 20 2.3.2. Distribusi Normal ............................................................................................... 21 2.3.3. Distribusi Gamma .............................................................................................. 21 2.3.4. Distribusi Weibull .............................................................................................. 22 2.3.5. Distribusi Lognormal ......................................................................................... 23 2.4 Penentuan Interval Perawatan Optimal .......................................................................... 23 2.5 Pengujian Hipotesa Distribusi Data (Test Goodness of Fit) .......................................... 25 2.5.1. Asumsi-asumsi ................................................................................................... 25 2.5.2. Hipotesa ............................................................................................................. 25 2.5.3. Statistik Uji ........................................................................................................ 26 2.5.4. Kaidah Pengambilan Keputusan ........................................................................ 26 2.6 Model Age Replacement ................................................................................................ 26 2.6.1. Biaya Penggantian .............................................................................................. 28 2.7 Mesin Multi Block .......................................................................................................... 30 BAB III METODOLOGI PENELITIAN 3.1 Flow Chart ..................................................................................................................... 32 3.2 Penjelasan Diagram Alir Penelitian ............................................................................... 33 BAB IV PENGUMPULAN DAN PENGOLAHAN DATA 4.1 Penjelasan Diagram Alir Penelitian ............................................................................... 39 4.1.1 Logo Perusahaan ................................................................................................ 39 4.1.2 Visi dan Misi Perusahaan ................................................................................... 40 4.1.3 Struktur Organisasi Perusahaan .......................................................................... 40 4.1.4 Layout Perusahaan .............................................................................................. 41
2.1 Mesin Multi Block .......................................................................................................... 41 4.3 Pengumpulan Data ......................................................................................................... 45 4.3.1 Data Waktu Antar Kerusakan ............................................................................. 46 4.3.2 Data Lama Perbaikan dan Lama Mesin Menganggur ........................................ 46 4.3.3 Data Biaya .......................................................................................................... 47 4.4 Pengolahan Data ............................................................................................................ 47 4.4.1 Penentuan Distribusi Data dan Parameter Keandalan ........................................ 47 4.4.2 Menentukan Fungsi Padat Probabilitas .............................................................. 50 4.4.3 Menentukan Fungsi Keandalan .......................................................................... 53 4.4.4 Menentukan Laju Kerusakan Komponen .......................................................... 56 4.4.5 Menentukan MTTF, MTTR, MTTDT ............................................................... 59 4.4.6 Penghitungan Biaya Penggantian Terencana (Cp) ............................................. 61 4.4.7 Biaya Tiap Kali Terjadi Kerusakan (Cf) ............................................................ 61 4.4.8 Menentukan Interval Perawatan Terencana yang Optimal dengan Metode Age Replacement ................................................................................................ 62 BAB V ANALISA DAN PEMBAHASAN 5.1 Analisa Data .................................................................................................................... 66 5.1.1 Analisis Pembahasan Untuk Estimasi Parameter ............................................... 66 5.1.2 Analisis Fungsi Padat Probabilitas Distribusi Weibull ...................................... 68 5.1.3 Analisis Fungsi Keandalan Komponen Mesin Mixer ........................................ 69 5.1.4 Analisis Laju Kerusakan .................................................................................... 69 5.1.5 Analisis Perhitungan MTTF (mean time to failure) ........................................... 70 5.1.6 Analisis Perhitungan MTTR (mean time to repair) ........................................... 71 5.1.7 Analisis Perhitungan MTTDT (mean time to down time) .................................. 71 5.2 Analisa Terhadap Kebijakan Interval Waktu Penggantian Terencana ........................... 72 5.3 Menentukan Waktu Penggantian Komponen pada Waktu Bersama .............................. 74 BAB VI PENUTUP 6.1 Kesimpulan ..................................................................................................................... 76 6.2 Saran ............................................................................................................................... 76 DAFTAR PUSTAKA .......................................................................................................... 78 LAMPIRAN.......................................................................................................................... 79
DAFTAR TABEL Tabel 4.1 Komponen Kritis Mesin Mixer ............................................................................. 45 Tabel 4.2 Frekuensi Kerusakan Komponen Mesin Mixer .................................................... 45 Tabel 4.3 Data Waktu Antar Kerusakan, Waktu Lama Perbaikan dan Waktu Lama Mesin Menganggur Pada Komponen Gardan ..................................................... 46 Tabel 4.4 Hasil Pengujian Distribusi Dengan Kolmogorov Smirnov ................................... 48 Tabel 4.5 Parameter Distribusi Komponen Gardan ............................................................... 50 Tabel 4.6 Hasil Perhitungan Fungsi Padat Probabilitas ........................................................ 52 Tabel 4.7 Hasil Perhitungan Fungsi Keandalan .................................................................... 55 Tabel 4.8 Hasil Perhitungan Laju Kerusakan ....................................................................... 58 Tabel 4.9 Perhitungan MTTF, MTTR,dan MTTDT ............................................................. 60 Tabel 4.10 Hasil Perhitungan Cp dan Cf .............................................................................. 62 Tabel 4.11 Nilai C(tp) Komponen Gardan dengan Metode Age Replacement ..................... 63 Tabel 4.12 Alternatif Biaya Penggantian Komponen Gardan ............................................... 65 Tabel 5.1 Data Waktu Antar Kerusakan, Waktu Lama Perbaikan dan Waktu Lama Mesin Menganggur................................................................................................ 67 Tabel 5.2 Hasil Perhitungan MTTF ...................................................................................... 70 Tabel 5.3 Hasil Perhitungan MTTR....................................................................................... 71 Tabel 5.4 Hasil Perhitungan MTTDT .................................................................................... 71 Tabel 5.5Perhitungan Total Biaya C(tp) Penggantian Awal Perusahaan .............................. 72 Tabel 5.6 Perbandingan Total Biaya C(tp) Awal dan (Cp) Interval Terencana ................... 73 Tabel 5.7 Biaya Minimum Pada Perhitungan Age Repalcement .......................................... 74 Tabel 5.8 Biaya Setelah Interval Penggantian Disesuaikan .................................................. 75 Tabel 5.9 Jadwal Penggantian ............................................................................................... 75
DAFTAR GAMBAR Gambar 2.1 Bagan Hubungan Antara Berbagai Bentuk Perawatan ..................................... 11 Gambar 2.2 Hubungan Biaya Pemeilharaan dengan Mutu Pemeliharaan ............................ 12 Gambar 2.3 Kurva Fungsi Padat Probabilitas ....................................................................... 14 Gambar 2.4 Fungsi Keandalan Sebagai Fungsi Waktu ........................................................ 15 Gambar 2.5 Grafik Keandalan dengan Perawatan ................................................................ 24 Gambar 2.6 Model Penggantian Pencegahan ....................................................................... 27 Gambar 2.7 Model Oprasi Model Age Replacement ............................................................ 27 Gambar 2.8 Distribusi Normal Pada Siklus Kerusakan ........................................................ 28 Gambar 2.9 Distribusi Normal Pada Eksponensial Waktu Siklus ......................................... 29 Gambar 2.10 Skema Mesin Multi Block ............................................................................... 30 Gambar 2.11 Mesin Multi Block ............................................................................................ 31 Gambar 3.1 Diagram Alir Penelitian .................................................................................... 32 Gambar 4.1 Logo Perusahaan ............................................................................................... 39 Gambar 4.2 Struktur Organisasi Perusahaan ........................................................................ 40 Gambar 4.3 Layout Perusahaan ............................................................................................ 41 Gambar 4.4 Mesin Press ....................................................................................................... 42 Gambar 4.5 Mesin Mixer ....................................................................................................... 42 Gambar 4.6 Mesin Conveyor ................................................................................................ 43 Gambar 4.7 Komponen Tampel ............................................................................................ 43 Gambar 4.8 Komponen Laker ............................................................................................... 44 Gambar 4.9 Komponen Pangkon .......................................................................................... 44 Gambar 4.10 Komponen Gardan .......................................................................................... 44 Gambar 4.11 Fungsi Padat Probabilitas Komponen Gardan ................................................ 53 Gambar 4.12 Fungsi Keandalan Komponen Gardan ............................................................ 56 Gambar 4.13 Laju Kerusakan Komponen Gardan ................................................................ 59 Gambar 4.14 Total Biaya Perawatan Komponen Gardan ..................................................... 64 Gambar 5.1 Fungsi Padat Probabilitas .................................................................................. 68 Gambar 5.2 Fungsi Keandalan .............................................................................................. 69 Gambar 5.3 Laju Kerusakan ................................................................................................. 70
DAFTAR LAMPIRAN Lampiran1 Menggunakan Software Statgraph ...................................................................... 78 Lampiran2 Menggunakan Software Mathcad Prime ............................................................. 84
DAFTAR PUSTAKA
Assauri, Sofjan. 1993, Manajemen Produksi dan Oprasi. Lembaga Penerbit Fakultas Ekonomi Universitas Indonesia. Boediono, dan Wayan Koster. 2001, Teori dan Aplikasi Statistika dan Probabilitas. PT. Remaja Rosda Karya Bandung. Jardine, A.K.S. 1973, Maintenance, Replacement and Reliability. Pitman Publishing. Corporation, Newyork. Kusnul Hadi. 1996, Teknik Manajemen Perawatan Mesin, Erlangga. Lewis, E.E. 1987, Introduction to Reliability Engineer, John Wiley & Sons, Inc., New York. Priyatna, Dwi. 2000, Keandalan dan Perawatan, Teknik Sistem Perkapalan, Institusu Teknologi Sepuluh November, Surabaya. Sukanto.1991, Manajemen Produksi Edisi 4. BPFE Yogyakarta. Suprianto, J.1991, Statistik Metode Teori dan Aplikasi. Erlangga.
