PERANCANGAN TROLI PEMINDAHAN GALON AIR MINERAL YANG ERGONOMIS
TUGAS AKHIR Diajukan Sebagai Salah Satu Syarat Untuk Memperoleh Gelar Sarjana Teknik Pada Jurusan Teknik Industri
Oleh : DANANG SAPUTRA 10852002754
FAKULTAS SAINS DAN TEKNOLOGI UNIVERSITAS ISLAM NEGERI SULTAN SYARIF KASIM RIAU PEKANBARU 2014
PERANCANGAN TROLI PEMINDAHAN GALON AIR MINERAL YANG ERGONOMIS Danang Saputra 1) Nofirza, S.T., M.T 2)
Jurusan Teknik Industri, Fakultas Sains dan Teknologi Universitas Islam Negeri (UIN) Sultan Syarif Kasim Riau
Abstrak
Proses Manual Material Handling dengan postur kerja yang tidak ergonomis akan menyebabkan cedera bagi operator, hal tersebut terjadi pada pemindahan galon air mineral mulai dari membawa pada lantai yang rata, menaiki anak tangga dan menaikkan ke atas dispenser. Penelitian ini bertujuan menghasilkan troli pemindahan galon air mineral yang dapat memperbaiki postur kerja, hasil perancangan ini dapat digunakan sebagai alat untuk menyelesaikan masalah pemindahan galon air mineral. Berdasarkan pengolahan data dengan menggunakan metode OWAS dapat diketahui bahwa dari sepuluh postur kerja sebelum perancangan, 90% postur memerlukan perbaikan sedangkan setelah dilakukan perancangan hanya terdapat tujuh postur kerja, yang 14% postur memerlukan perbaikan. Dari keterangan diatas dapat disimpulkan bahwa telah terjadi perbaikan postur kerja setalah dilakukan perancangan. Penerapan alat yang dirancang dapat memperbaiki postur kerja menjadi lebih ergonomis.
Kata kunci: Manual Material Handling, Postur kerja, OWAS
1)
2)
Mahasiswa Fakultas Sains dan Teknologi Universitas Islam Negeri Sultan Syarif Kasim Riau Dosen Fakultas Sains dan Teknologi Universitas Islam Negeri Sultan Syarif Kasim Riau
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DESIGN OF TROLLEY GALLONS WATER REMOVAL WITH ERGONOMIC Danang Saputra 1) Nofirza, S.T., M.T 2)
Department of Industrial Engineering, Faculty of Science and Technology State Islamic University (UIN) Sultan Syarif Kasim Riau
Abstract
Manual Material Handling processes with non-ergonomic working posture is going to cause injury to the operator, it the process of moving gallon mineral water from carrying on a flat floor, climb stairs and raise it to the top of the dispenser. This study aims to produce a gallon of mineral water removal trolley which can improve posture work, the results of this design can be used as a tool to solve problems gallon mineral water removal. Based on data processing using OWAS can be seen that the ten working posture prior to the design, posture requires a 90 % improvement after did the design there are only seven working posture, the posture requires a 14 % improvement. From the above description it can be concluded that there has been improvement of work postures after the design is done. Application of tools designed to improve posture becomes more ergonomic working.
Key Word: Manual Material Handling, Working Postures, OWAS
1)
2)
Students Faculty of Science and Technology Islamic University of Sultan Syarif Kasim Riau Lecturer Faculty of Science and Technology Islamic University of Sultan Syarif Kasim Riau
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KATA PENGANTAR
Assalamu’alaikum Wr,Wb. Puji syukur kehadirat Allah SWT, yang telah melimpahkan rahmat dan hidayahnya, sehingga penulis dapat menyelesaikan penulisan laporan Tugas Akhir ini tepat pada waktunya. Laporan Tugas Akhir ini penulis ajukan sebagai salah satu syarat guna memperoleh gelar Sarjana Teknik pada Fakultas Sains dan Teknologi Universitas Islam Negeri Sultan Syarif Kasim Riau. Adapun judul dari Laporan Tugas Akhir yang penulis sajikan adalah “Perancangan Troli Pemindahan Galon Air Mineral yang Ergonomis”. Pada kesempatan ini, penulis ingin menyampaikan rasa terimakasih dan penghargaan yang tulus kepada semua pihak yang telah banyak memberi petunjuk, bimbingan, dorongan dan bantuan dalam penulisan laporan Tugas Akhir ini, baik secara langsung maupun tidak langsung, terutama pada: 1. Allah SWT, Tuhan sekaligus Pengatur Kehidupan yang telah memberikan kesempatan bagi penulis untuk menyelesaikan Tugas Akhir hingga selesai. 2. Bapak Ismu Kusumanto, M.T. selaku Ketua Jurusan Teknik Industri Fakultas Sains dan Teknologi UIN Suska Riau, yang telah memberikan izin kepada penulis untuk melakukan Tugas Akhir. 3. Ibu Nofirza, ST. M.Sc. selaku dosen pembimbing yang telah banyak meluangkan waktu, tenaga dan pikiran dalam membimbing dan memberikan petunjuk yang sangat berharga dalam penulisan laporan ini. 4. Ibu Merry Siska, ST M.Sc dan Ibu Neng Sri Novi Fitri Yani, ST, M.Tech, M.Gt. selaku penguji yang selalu memberikan masukan dan saran demi membangun ke arah sempurnanya laporan tugas akhir ini. 5. Kepada seluruh Dosen Teknik Industri yang telah dengan ikhlas menyampaikan ilmunya kepada penulis.
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6. Kedua orang tua penulis yang tercinta Ayahanda Marman dan Ibunda Lasmi yang telah banyak memberikan dukungan moril dan materil serta do’a restu kepada penulis sehingga dapat menyelesaikan Tugas Akhir ini. 7. Kepada Kakak ku Mbak Wiwin Widyaningsih, S.Pt, beserta Mas Ismanto, saudaraku Mas Tego Herin Saptono, terima kasih untuk semua dukungan yang telah kalian berikan. Selanjutnya kedua keponakan ku tersayang Adelia Delapuspa dan Arkan Fadil Atmadeva, semoga kalian jadi anak yang sholeh/sholehah. 8. Kepada Satu Nama yang Spesial Buat Penulis “Mei Linda Wati” terima kasih atas do’a dan dukungannya selama ini sehingga penulis dapat menyelesaikan Tugas Akhir ini. 9. Rekan-rekan Teknik Industri. Eko, Suken, Novri, Duwi, Adit, Benk, Pujadi, Tyozil, Maulana, Salamun, Mas Rif, Otang, Sitta, Ilham Ocu, Alfian, Lazim, Sahidin, Dewi, Ifah, Anda, Ruby, Uya, Wira, Sabri dan rekan-rekan lainnya baik Senior maupun Junior yang tidak bisa dituliskan satu persatu. Terima kasih telah banyak membantu, sukses untuk kita semua...Amin Dalam penulisan laporan Tugas Akhir ini, penulis menyadari masih terdapat kekurangan baik dari segi pembahasan maupun dari segi penggunaan kata-kata. Untuk itu penulis mengharapkan adanya kritik maupun saran yang bersifat membangun atau bertujuan untuk menyempurnakan isi dari laporan tugas akhir ini serta bermanfaat bagi semua pihak yang berkepentingan pada umumnya dan bagi penulis untuk mengamalkan ilmu pengetahuan di tengah-tengah masyarakat Semoga Allah S.W.T. memberikan balasan atas jasa pihak-pihak yang membantu di atas dan semoga laporan tugas akhir ini bermanfaat bagi kita semua.
Wassalam Pekanbaru, Penulis,
Januari 2014
(DANANG SAPUTRA)
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DAFTAR ISI Halaman HALAMAN JUDUL ............................................................................................. i LEMBAR PERSETUJUAN .................................................................................. ii LEMBAR PENGESAHAN .................................................................................. iii LEMBAR HAK ATAS KEKAYAAN INTELEKTUAL ................................... iv LEMBAR PERNYATAAN ................................................................................... v LEMBAR PERSEMBAHAN ............................................................................... vi ABSTRAK ............................................................................................................ vii ABSTRACK .......................................................................................................... viii KATA PENGANTAR ........................................................................................... ix DAFTAR ISI .......................................................................................................... xi DAFTAR GAMBAR ........................................................................................... xvi DAFTAR TABEL ............................................................................................... xix DAFTAR LAMPIRAN ....................................................................................... xxi
BAB I
PENDAHULUAN 1.1
Latar Belakang ························································· I-1
1.2
Rumusan Masalah ····················································· I-6
1.3
Tujuan Penelitian ······················································ I-7
1.4
Batasan Masalah ························································ I-7
1.5
Manfaat Penelitian······················································ I-7
1.6
Posisi Penelitian ························································ I-8
1.7
Sistematika Penulisan Laporan ······································ I-8
BAB II LANDASAN TEORI 2.1
Ergonomi ································································ II-1
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2.2
2.1.1
Tujuan Ergonomi············································· II-3
2.1.2
Aspek-aspek Pendekatan Ergonomi ······················· II-4
2.1.3
Aplikasi ergonomi············································ II-4
Antropometri ··························································· II-6 2.2.1
Data Antropometri dan Pengukurannya ···················· II-8
2.2.2
Aplikasi Data Antropometri dalam Perancangan Produk (Fasilitas Kerja) ······································· II-12
2.3
Manual Material Handling············································ II-13
2.4 Konsep Persentil ························································ II-14 2.5 Estimasi Biaya Produksi (Manufacturing Cost)···················· II-16 2.6 Postur Kerja······························································ II-17 2.7 Beban Angkat ··························································· II-18 2.8 Nordic Body Map ······················································· II-18 2.9 Metode Analisis Postur Kerja OWAS ······························· II-19
BAB III METODOLOGI PENELITIAN 3.1
Tahapan Penelitian ····················································· III-1
3.2
Studi Pendahuluan ····················································· III-2
3.3
Identifikasi Masalah ··················································· III-2
3.4
Perumusan Masalah ···················································· III-2
3.5
Menetapkan Tujuan Penelitian ······································· III-2
3.6
Pengumpulan Data ····················································· III-3
3.7
3.8
3.6.1
Data Primer····················································· III-3
3.6.2
Data Sekunder·················································· III-4
Pengolahan Data ······················································· III-4 3.7.1
Data Antropometri Orang Indonesia Perempuan········· III-4
3.7.2
Pengolahan Data OWAS····································· III-4
Konsep Rancangan ···················································· III-5
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3.9
Estimasi Biaya Produksi ··············································· III-5
3.10 Perancangan Alat ······················································· III-6 3.11 Pengujian Alat··························································· III-6 3.12 Analisa Hasil ···························································· III-6 3.13 Kesimpulan dan Saran ················································· III-7
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA 4.1
Pengumpulan Data ····················································· IV-1 4.1.1 Data Antropometri············································· IV-1 4.1.2 Data Karakteristik Galon Air Mineral ······················ IV-1
4.2
Pengolahan Data menggunakan Metode OWAS··················· IV-2
4.3
Penilaian Postur Kerja sebelum Perancangan ······················ IV-2 4.3.1 Postur Kerja Pertama·········································· IV-3 4.3.2
Postur Kerja Kedua············································ IV-4
4.3.3 Postur Kerja Ketiga ··········································· IV-6 4.3.4 Postur Kerja Keempat········································· IV-7 4.3.5 Postur Kerja Kelima··········································· IV-9 4.3.6 Postur Kerja Keenam ········································· IV-10 4.3.7 Postur Kerja Ketujuh·········································· IV-12 4.3.8
Postur Kerja Kedelapan······································· IV-13
4.3.9
Postur Kerja Kesembilan ····································· IV-15
4.3.10 Postur Kerja Kesepuluh······································· IV-16 4.4
Pengolahan Data menggunakan Software WinOwas ·············· IV-19 4.4.1
Input Data······················································· IV-19
4.4.2 Pengolahan dengan Software WinOWAS sebelum perancangan····················································· IV-20 4.5
Konsep Rancangan ····················································· IV-25
4.6
Estimasi Biaya Produksi ··············································· IV-25
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4.7
4.8
Perancangan Alat ······················································· IV-26 4.7.1
Lebar Bahu ····················································· IV-27
4.7.2
Panjang Telapak Tangan ····································· IV-27
Pengujian Alat··························································· IV-27 4.8.1 Postur Kerja Pertama setelah perancangan ················ IV-28 4.8.2
Postur Kerja Kedua setelah perancangan ·················· IV-29
4.8.3 Postur Kerja Ketiga setelah perancangan ·················· IV-31 4.8.4 Postur Kerja Keempat setelah perancangan ··············· IV-32 4.8.5 Postur Kerja Kelima setelah perancangan ················· IV-34 4.8.6 Postur Kerja Keenam setelah perancangan ················ IV-35 4.8.7 Postur Kerja Ketujuh setelah perancangan················· IV-37 4.9
Pengolahan data dengan Software WinOWAS setelah perancangan ···················································· IV-39
BAB V ANALISA 5.1
Analisa Penilaian Postur Kerja dengan menggunakan Metode OWAS ·························································· V-1
5.2
5.1.1
Analisa Postur Kerja sebelum dilakukan perancangan ·· V-1
5.1.2
Analisa Postur Kerja setelah dilakukan perancangan···· V-2
Analisa Perbandingan Postur Kerja sebelum perancangan dengan setelah perancangan··········································· V-3
5.3
Analisa Biaya ···························································· V-4
5.4
Analisa Perbandingan Troli Pemindahan Galon Air Mineral dengan Alat yang Telah Ada································ V-4
BAB VI PENUTUP 6.1
Kesimpulan ······························································ VI-1
6.2
Saran······································································ VI-2
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DAFTAR PUSTAKA LAMPIRAN
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DAFTAR GAMBAR Halaman Gambar 1.1
Membawa galon pada lantai yang rata ······························ I-3
Gambar 1.2
Membawa galon melewati anak tangga ····························· I-3
Gambar 1.3
Menaikkan galon ke dispenser········································ I-4
Gambar 1.4
Alat bantu yang sudah ada ············································ I-5
Gambar 2.1
Antropometri Posisi Berdiri··········································· II-9
Gambar 2.2
Antropometri Tangan ·················································· II-10
Gambar 2.3
Antropometri Posisi Duduk ··········································· II-10
Gambar 2.4
Antropometri Kepala··················································· II-11
Gambar 2.5
Antropometri Kaki ····················································· II-15
Gambar 2.6
Kurva Distribusi Normal dengan Data Antropometri 95 Persentil ······························································ II-12
Gambar 2.7
Nordic Body Map ······················································ II-19
Gambar 2.8
Klasifikasi sikap kerja bagian punggung ···························· II-20
Gambar 2.7
Klasifikasi sikap kerja bagian lengan ································ II-21
Gambar 2.8
Klasifikasi sikap kerja bagian kaki··································· II-21
Gambar 3.1
Flow Chart Metodologi Penelitian ·································· III-1
Gambar 4.1
Karakteristik Galon····················································· IV-2
Gambar 4.2
Postur Kerja Pertama··················································· IV-3
Gambar 4.3
Postur Kerja Kedua····················································· IV-4
Gambar 4.4
Postur Kerja Ketiga····················································· IV-6
Gambar 4.5
Postur Kerja Keempat·················································· IV-7
Gambar 4.6
Postur Kerja Kelima···················································· IV-9
Gambar 4.7
Postur Kerja Keenam··················································· IV-11
Gambar 4.8
Postur Kerja Ketujuh ··················································· IV-12
Gambar 4.9
Postur Kerja Kedelapan················································ IV-14
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Gambar 4.10 Postur Kerja Kesembilan ·············································· IV-15 Gambar 4.11 Postur Kerja Kesepuluh················································ IV-17 Gambar 4.12 Input latar belakang informasi ········································ IV-19 Gambar 4.13 Input fase kerja·························································· IV-20 Gambar 4.14 Tampilan Layar Pengamatan·········································· IV-21 Gambar 4.15 Hasil Pengamatan······················································· IV-21 Gambar 4.16 Grafik Rekomendasi Perbaikan Seluruh Tahapan Kerja·········· IV-22 Gambar 4.17 Grafik Rekomendasi Perbaikan Tahapan Kerja Pada Proses Mengambil ······················································ IV-23 Gambar 4.18 Grafik Rekomendasi Perbaikan Tahapan Kerja Pada Proses Membawa ······················································· IV-24 Gambar 4.19 Grafik Rekomendasi Perbaikan Tahapan Kerja Pada Proses Meletakkan······················································ IV-25 Gambar 4.20 Hasil Perancangan ······················································ IV-27 Gambar 4.21 Postur Kerja Pertama setelah perancangan ························· IV-28 Gambar 4.22 Postur Kerja Kedua setelah perancangan ··························· IV-29 Gambar 4.23 Postur Kerja Ketiga setelah perancangan ··························· IV-31 Gambar 4.24 Postur Kerja Keempat setelah perancangan ························ IV-33 Gambar 4.25 Postur Kerja Kelima setelah perancangan ·························· IV-34 Gambar 4.26 Postur Kerja Keenam setelah perancangan ························· IV-36 Gambar 4.27 Postur Kerja Ketujuh setelah perancangan·························· IV-37 Gambar 4.28 Rekapitulasi Hasil Analisis Postur Kerja setelah perancangan ·· IV-39 Gambar 4.29 Grafik Hasil Analisis Postur Kerja keseluruhan setelah perancangan ···················································· IV-40 Gambar 4.30 Grafik Hasil Analisis Postur Kerja pada fase mengambil setelah perancangan ···················································· IV-40 Gambar 4.31 Grafik Hasil Analisis Postur Kerja pada fase membawa setelah perancangan ···················································· IV-41
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Gambar 4.32 Grafik Hasil Analisis Postur Kerja pada fase meletakkan setelah perancangan ···················································· IV-42 Gambar 6.1
Troli Pemindahan Galon Air Mineral ······························· VI-1
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DAFTAR TABEL Halaman Tabel 1.1 Persentase Keluhan Pekerja················································ I-4 Tabel 1.2 Posisi Penelitian Tugas Akhir ············································· I-8 Tabel 2.1 Macam Persentil Untuk Data Berdistribusi Normal ··················· II-15 Tabel 2.2 Batas Beban Angkat dan Tindakan yang Harus Dilakukan ··········· II-18 Tabel 2.3 Kategori tindakan kerja OWAS ··········································· II-24 Tabel 3.1 Item yang digunakan dalam perancangan Troli Pemindahan Galon Air Mineral··························································· III-6 Tabel 4.1 Penilaian Postur Kerja Pertama ·········································· IV- 3 Tabel 4.2 Kode Postur Kerja Pertama ················································ IV- 4 Tabel 4.3 Penilaian Postur Kerja Kedua ············································· IV- 5 Tabel 4.4 Kode Postur Kerja Kedua ················································· IV- 5 Tabel 4.5 Penilaian Postur Kerja Ketiga ············································· IV- 6 Tabel 4.6 Kode Postur Kerja Ketiga ················································· IV- 7 Tabel 4.7 Penilaian Postur Kerja Keempat ········································· IV- 8 Tabel 4.8 Kode Postur Kerja Keempat ··············································· IV- 8 Tabel 4.9 Penilaian Postur Kerja Kelima ··········································· IV- 9 Tabel 4.10 Kode Postur Kerja Kelima ················································· IV- 10 Tabel 4.11 Penilaian Postur Kerja Keenam ··········································· IV- 11 Tabel 4.12 Kode Postur Kerja Keenam················································ IV- 11 Tabel 4.13 Penilaian Postur Kerja Ketujuh ··········································· IV- 12 Tabel 4.14 Kode Postur Kerja Ketujuh ················································ IV- 13 Tabel 4.15 Penilaian Postur Kerja Kedelapan ········································ IV- 14 Tabel 4.16 Kode Postur Kerja Kedelapan ············································· IV- 14 Tabel 4.17 Penilaian Postur Kerja Kesembilan······································· IV- 15 Tabel 4.18 Kode Postur Kerja Kesembilan ··········································· IV- 16
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Tabel 4.19 Penilaian Postur Kerja Kesepuluh ········································ IV- 17 Tabel 4.20 Kode Postur Kerja Kesepuluh ············································· IV- 17 Tabel 4.21 Rekapitulasi Pengolahan Data Owas ····································· IV- 18 Tabel 4.22 Estimasi Biaya Produksi ··················································· IV- 26 Tabel 4.23 Penilaian Postur Kerja Pertama setelah perancangan ·················· IV- 28 Tabel 4.24 Kode Postur Kerja Pertama setelah perancangan······················· IV- 29 Tabel 4.25 Penilaian Postur Kerja Kedua setelah perancangan ···················· IV- 30 Tabel 4.26 Kode Postur Kerja Kedua setelah perancangan························· IV- 30 Tabel 4.27 Penilaian Postur Kerja ketiga setelah perancangan ···················· IV- 31 Tabel 4.28 Kode Postur Kerja ketiga setelah perancangan ························· IV- 32 Tabel 4.29 Penilaian Postur Kerja Keempat setelah perancangan ················· IV- 33 Tabel 4.30 Kode Postur Kerja Keempat setelah perancangan······················ IV- 33 Tabel 4.31 Penilaian Postur Kerja Kelima setelah perancangan ··················· IV- 34 Tabel 4.32 Kode Postur Kerja Kelima setelah perancangan························ IV- 35 Tabel 4.33 Penilaian Postur Kerja Keenam setelah perancangan·················· IV- 36 Tabel 4.34 Kode Postur Kerja Keenam setelah perancangan ······················ IV- 36 Tabel 4.35 Penilaian Postur Kerja Ketujuh setelah perancangan ·················· IV- 37 Tabel 4.36 Kode Postur Kerja Ketujuh setelah perancangan······················· IV- 38 Tabel 4.37 Rekapitulasi Pengolahan Data Owas setelah perancangan············ IV- 38 Tabel 5.1 Perbandingan Postur Kerja Sebelum dan Setelah Perancangan ······ V- 3 Tabel 5.2 Perbandingan Hasil Perancangan dengan Alat yang Telah Ada ····· V- 5 Tabel 6.1 Data dan Ukuran yang digunakan dalam perancangan ················ VI- 2
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