TAKARIR
Berikut ini adalah padanan kata bahasa asing dalam bahasa Indonesia yang digunakan dalam menyusun laporan tugas akhir ini : Mother Yarn
: Bahan baku berupa filament benang Nylon yang terdiri dari 16 filamen tunggal.
Bobin
: Besi berbentuk pipa yang digunakan untuk menggulung benang pada proses splitting.
Splitting
: Proses pemisahan filament Mother Yarn menjadi monofilament.
Ospirator
: Mesin sedot yang digunakan untuk membersihkan bahan baku Mother Yarn.
Monofilament
: Produk Sub Divisi Bunsen berupa benang Nylon yang berupa filamentfilament tunggal.
DAFTAR ISI
HALAMAN JUDUL .......................................................................................................i SURAT PERNYATAAN KEASLIAN TUGAS AKHIR ............................................. .ii SURAT KETERANGAN SELESAI TUGAS AKHIR PERUSAHAAN ..................... iii LEMBAR PENGESAHAN DOSEN PEMBIMBING .................................................. iv LEMBAR PENGESAHAN DOSEN PENGUJI............................................................ .v HALAMAN PERSEMBAHAN ....................................................................................vi HALAMAN MOTTO .................................................................................................vii KATA PENGANTAR ................................................................................................ viii ABSTRAKSI ................................................................................................................. x TAKARIR ......................................................................................................................xi DAFTAR ISI.................................................................................................................xii DAFTAR TABEL.......................................................................................................xvii DAFTAR GAMBAR .................................................................................................. xix BAB I PENDAHULUAN 1.1
Latar Belakang masalah ........................................................ ................1
1.2 Rumusan Masalah .................................................................. ................4 1.3 Batasan Masalah .................................................................... ................4 1.4 Tujuan Penelitian ................................................................... ................5 1.5 Manfaat Penelitian ................................................................. ................5 1.6 Sistematika Penulisan ............................................................ ................6
BAB II KAJIAN LITERATUR 2.1 Pendahuluan ........................................................................... ................8 2.2 Produktivitas.........................................................................................10 2.2.1 Pengertian Produktivitas.............................................................10 2.2.2 Metode-metode Pengukuran Produktivitas................................12 2.2.3 Produktivitas Kerja Manusia dan Cara Pengukurannya ........... .12 2.3 Tes Kecukupan dan Keseragaman Data ............................... ..............13 2.3.1 Tes Kecukupan Data .................................................... ..............13 2.3.2 Tes Keseragaman Data................................................................14 2.4
Penentuan Faktor Penyesuaian dan Kelonggaran .................. ..............15 2.4.1 Faktor Penyesuaian ...................................................... ..............15 2.4.2 Faktor Kelonggaran.....................................................................15
2.5
Menentukan Waktu Siklus, Waktu Normal, dan Waktu Baku ..........................................................................................17 2.5.1 Menghitung Waktu Siklus dan Waktu Normal...........................17 2.5.2 Menghitung Waktu Baku............................................................18
2.6 Metode Work Load Analysis (Analisis Beban Kerja)...........................18 2.7 Simulasi.................................................................................................20 2.7.1 Pemodelan Sistem ........................................................ ..............21 2.7.1.1 Definisi Sistem ............................................................... .21 2.7.1.2 Definisi Model.................................................................21 .
2.7.2 Pengertian Simulasi Sistem ........................................................ .23 2.7.2.1 Bagian-Bagian Model Simulasi .................................... .24 2.7.2.2 Langkah-langkah Simulasi..............................................26
2.7.2.3 Keuntungan Simulasi......................................................28 2.7.2.4 Kerugian Simulasi...........................................................30 2.8
Distribusi Data......................................................................................30
2.9
Validasi Model………………………..................................................44
2.10 Analisa Output Hasil Simulasi…………………….........................…..47 2.11 Perangkat Lunak Promodel 7.0………………………..................…...49 2.11.1 Bahasa Pemrograman Simulasi………………………………..49 2.11.2 Keunggulan Promodel………………………………………...50 2.11.3 Promodel dalam Pemodelan Sistem…………………………..51 2.11.4 Stat Fit………………………………………………………...52
BAB III METODE PENELITIAN 3.1 Penentuan Objek Penelitian .................................................... …….….53 3.2 Identifikasi Masalah ................................................................ ..............53 3.3 Metode Pengumpulan Data ..................................................... ..............54 3.3.1 Pengumpulan Data.......................................................................54 3.3.2 Data Yang Dibutuhkan................................................................55 3.4 Pengolahan Data ..................................................................... ..............56 3.5 Pembahasan............................................................................. ………..57 3.6 Kesimpulan dan Saran ............................................................ ..............57 3.7 Kerangka Pemecahan Masalah ............................................... ..............58
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA 4.1
Pengumpulan Data ............................................................................... 59 4.1.1 Sejarah Perusahaan .................................................................... 59 4.1.2 Data Produk yang Dihasilkan ..................................................... 61 4.1.3 Data Tenaga Kerja ...................................................................... 61 4.1.4 Bahan baku ................................................................................. 62 4.1.4.1 Bahan Baku Utama ......................................................... 62 4.1.4.2 Bahan Baku Pendukung .................................................. 63 4.1.5 Data Mesin-Mesin Produksi…………….....................................63 4.1.6 Data Waktu Proses.......................................................................64 4.1.7 Data Proses Produksi ................................................................... 67 4.1.8 Data Produksi .............................................................................. 70
4.2
Pengolahan Data ................................................................................... 72 4.2.1 Pengukuran Waktu Baku ............................................................. 72 4.2.2 Metode Work Load Analysis ....................................................... 78 4.2.3 Validasi Data Input dan Pengolahan Distribusi Waktu ......................................................................... 80 4.2.4 Membangaun Model Simulasi Menggunakan Software ProModel 7.0........... ................................................................... 84 4.2.5 Menjalankan Program................................................... .............. 86 4.2.6 Penentuan Fase Steady State........................................ ............... 86
4.2.7 Output Hasil Simulasi Model Awal................................. ........... 90 4.2.8 Validasi Output Simulasi Model Awal................................. ...... 90 4.2.9 Model Simulasi Hasil Metode Work Load Analysis............ ....... 93 4.2.10 Membangun Model Skenario.............. ..................................... 95
BAB V PEMBAHASAN 5.1 Analisa Jumlah Tenaga Kerja dengan Metode Work Load Analysis…..97 5.2 Analisa Model Awal………….................................. ........................... 98 5.3
Analisa Simulasi Model dari Metode Work Load Analysis.............. ... 99
5.4
Analisa Simulasi Model Skenario........................................................ 99
BAB VI KESIMPULAN DAN SARAN 6.1 Kesimpulan…………………………………………………………….103 6.2 Saran…………………………………………………………………..104
DAFTAR PUSTAKA LAMPIRAN
DAFTAR TABEL
Tabel 4.1
Tabel Data Mesin .............................................................................. 63
Tabel 4.2
Tabel Waktu Proses Penyinaran dengan Ulraviolet.......................... 64
Tabel 4.3
Tabel Waktu Proses Ospirator .......................................................... 64
Tabel 4.4
Tabel Waktu Proses Perajutan .......................................................... 65
Tabel 4.5
Tabel Proses Maintenance Splitting.................................................. 65
Tabel 4.6
Tabel Waktu Proses Packing ............................................................ 66
Tabel 4.7
Tabel Waktu Proses Quality Control ................................................ 66
Tabel 4.8
Tabel Data Produksi .......................................................................... 70
Tabel 4.9
Tabel waktu proses penyinaran dengan ultraviolet........................... 72
Tabel 4.10
Tabel kecukupan data. ...................................................................... 73
Tabel 4.11
Tabel keseragaman data pengamatan waktu baku ............................ 75
Tabel 4.12
Tabel Performance Rating ............................................................... 75
Tabel 4.13
Tabel penentuan allowance tenaga kerja tiap stasiun kerja…….......76
Tabel 4.14
Tabel Perhitungan Waktu Normal (WN) dan Waktu Baku (WB).....78
Tabel 4.15
Tabel waktu proses penyinaran dengan ultraviolet .......................... 81
Tabel 4.16
Tabel uji distribusi waktu proses........................................................83
Tabel 4.17
Tabel data kumulatif output produksi tiap batch .............................. 87
Tabel 4.18
Tabel data relatif output produksi tiap batch .................................... 88
Tabel 4.19
Tabel hasil simulasi produksi bunsen ............................................... 90
Tabel 4.20
Tabel Perbandingan output simulasi dengan sistem nyata Bunsen ... 91
Tabel 4.21
Tabel Descriptive statistic sistem nyata dan hasil simulasi ............... 91
Tabel 4.22
Tabel perbandingan utilitas tenaga kerja dan output produk dari WLA ............................................................................... 94
Tabel 5.1
Tabel perbandingan utilitas tenaga kerja dan output produk dari model skenario... ....................................................................... 100
DAFTAR GAMBAR
Gambar 2.1
Gambar grafik distribusi Beta ........................................................... 32
Gambar 2.2
Gambar grafik distribusi Erlang........................................................ 33
Gambar 2.3
Gambar grafik distribusi Eksponensial ............................................. 33
Gambar 2.4
Gambar grafik distribusi Gamma...................................................... 34
Gambar 2.5
Gambar grafik distribusi Lognormal ................................................ 35
Gambar 2.6
Gambar grafik distribusi Normal ...................................................... 36
Gambar 2.7
Gambar grafik distribusi Pearson 5................................................... 37
Gambar 2.8
Gambar grafik distribusi Pearson 6................................................... 38
Gambar 2.9
Gambar grafik distribusi Triangular ................................................. 39
Gambar 2.10
Gambar grafik distribusi Uniform .................................................... 39
Gambar 2.11
Gambar grafik distribusi Weilbull .................................................... 40
Gambar 2.12
Gambar grafik distribusi Binomial ................................................... 41
Gambar 2.13
Gambar grafik distribusi Uniform Descrete ..................................... 42
Gambar 2.14
Gambar grafik distribusi Geometric.... ............................................. 43
Gambar 2.15
Gambar grafik distribusi Poisson....... ............................................... 43
Gambar 3.1
Gambar Diagram Alir Kerangka Penelitian ...................................... 58
Gambar 4.1
Gambar alur proses produksi ............................................................. 67
Gambar 4.2
Gambar data waktu proses pada Stat Fit ........................................... 81
Gambar 4.3
Gambar distribusi data pada Stat Fit ................................................. 82
Gambar 4.4
Gambar Export Fit Pada Stat Fit ....................................................... 82
Gambar 4.5
Gambar grafik Distribusi Triangular................................................. 83
Gambar 4.6
Gambar model awal…………………………………………….…...85
Gambar 4.7
Gambar grafik fase Warm-Up - Steady State .................................... 89
