TUGAS AKHIR SKRIPSI PENENTUAN INTERVAL PERAWATAN MESIN BUCKET ELEVATOR PADA KOMPONEN CHAIN DENGAN METODE ANALISA KEANDALAN DI PT. SEMEN INDONESIA TBK.
DisusunOleh :
Kukuh Prabowo 09540069
JURUSAN TEKNIK INDUSTRI FAKULTAS TEKNIK UNIVERSITAS MUHAMMADIYAH MALANG 2015
KATA PENGANTAR
SyukurAlhamdulillah kami haturkankehadirat Allah Subhanahuwata’ alaatasrahmatNyasehinggamakalah
penelitian
inidapatterselesaikandenganlancartanpaadanyasuatuhalangan yang berarti. Keberhasilanpenulisanmakalah
penelitian
initentunyatidaklepasdariberbagaipihak
yang
senantiasamemberikanbimbingandanpengarahanselamaini.Untukinipenulismenya mpaikan rasa terimakasih yang sebesar-besarnyakepada : 1. Kedua
Orang
Tua
(IbudanBapak)
yang
tiadahentimemberikandukungansertado’atanpapernahdimintasertakakakda nadik
yang
selalumemberikanperhatian,
semangat,
do’adandukunganselamaini. 2. Bapak Ir. HM Kholik,MT. selakuDosenPembimbing I. 3. BapakM. Irwan Pambudhiarto,ST, MT. selakuDosenPembimbing II 4. BapakIlyasMas'udin, M.LogScm, Ph.DselakuDosen Penguji I. 5. Ibu Dian Palupy, ST, MT. selakuDosenPenguji II. 6. SeluruhBapak/IbuDosendan
Tata
Usaha,
JurusanTeknikIndustriFakultasTeknikUniversitasMuhammadiyah Malang. 7. Seluruhpihak di PT. SEMEN INDONESIATbk. Gresik. 8. Teman-teman yang selalu memberi semangat dan do’a Dalampenulisanmakalah
ini,
penelitiberusahasemaksimalmungkinuntukmemperolehhasil
yang
sebaik-
baiknya.Namundemikiankarenaketerbatasanpeneliti sendiri,makalahinimasihbanyakkekurangandanmasihjauhdarikesempurnaan. Untukitukritikdan
saran
sangatpeneliti
harapkangunaperbaikanpenulisanmakalahini. Harapanpeneliti
semoga
makalah
sederhanainidapat
bermanfaatdanbergunasebagaibahanpertimbangandalampenulisanpenelitian yang serupa.Malang, 15 Mei 2015
DAFTAR ISI
ISI
HALAMAN
LEMBAR JUDUL................................................................................................
i
LEMBAR PENGESAHAN..................................................................................
ii
SURAT PERNYATAAN KEASLIAN...............................................................
iii
BERITA ACARA UJIAN TUGAS AKHIR........................................................
iv
LEMBAR BIMBINGAN TUGAS AKHIR.........................................................
v
SURAT KETERANGAN PENELITIAN...........................................................
vi
KATA PENGANTAR.........................................................................................
vii
ABSTRAKSI.......................................................................................................
viii
DAFTAR ISI........................................................................................................
ix
DAFTAR TABEL................................................................................................
x
DAFTAR GAMBAR...........................................................................................
xi
DAFTAR LAMPIRAN........................................................................................
xii
BAB I
PENDAHULUAN
1.1 Latar Belakang................................................................................................
1
1.2 Rumusan Masalah...........................................................................................
2
1.3 Tujuan Penelitian............................................................................................
3
1.4 Manfaat Penelitian..........................................................................................
3
1.5 Batasan Masalah dan Asumsi.........................................................................
3
BAB II
LANDASAN TEORI
2.1 Deskripsi Keandalan.......................................................................................
5
2.1.1 Model Matematis Keandalan...............................................................
6
2.1.2 Fungsi Keandalan.................................................................................
6
2.1.3 Mean Time To Failure (MTTF)...........................................................
7
2.1.4 Fungsi laju Kerusakan (Hazard Fungtion)...........................................
8
2.1.5 Fungsi Distribusi Kerusakan................................................................
9
2.1.6 Mean Time Between Failure (MTBF).................................................
12
2.1.7 Kurva Laju Kerusakan.........................................................................
12
2.2 Pengertian Perawatan......................................................................................
14
2.2.1 Tujuan Perawatan.................................................................................
14
2.2.2 Jenis-Jenis Perawatan...........................................................................
15
2.2.2.1 Perawatan Terencana..............................................................
15
2.2.2.2 Perawatan Tidak Terencana....................................................
18
2.3 Pengujian Kecocokan Data.............................................................................
20
2.3.1 Pengujian Chi Square (Goodness of Fit)..............................................
20
2.4 Ketersediaan (Availabilty)..............................................................................
21
2.5 Biaya Perawatan dan Perbaikan......................................................................
23
2.6 Penentuan Interval waktu Perawatan..............................................................
23
2.7 Mesin Bucket elevator....................................................................................
25
BAB III METODOLOGI PENELITIAN 3.1 Flow Chart......................................................................................................
26
3.2 Survey Perusahaan..........................................................................................
27
3.3 Perumusan Masalah dan tujuan Masalah........................................................
27
3.4 Tinjauan Pustaka.............................................................................................
27
3.5 Metode Pengumpulan data dan Pengolahan Data...........................................
27
3.6 Pengumpulan Data..........................................................................................
28
3.6.1 Biaya Kerusakan..................................................................................
29
3.6.2 Biaya Perawatan Terencana.................................................................
29
3.7 Pengolahan dan Analisa Data.........................................................................
30
3.8 Analisa Pembahasan.......................................................................................
31
3.9 Kesimpulan dan Saran....................................................................................
32
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA 4.1 Tinjauan Perusahaan.......................................................................................
33
4.1.1 Profil Perusahaan.................................................................................
33
4.1.2 Proses Perusahaan................................................................................
35
4.1.2.1 Penyiapan Bahan Baku..............................................................
35
4.1.2.3 Crusher......................................................................................
36
4.1.2.4 Raw Mill....................................................................................
37
4.1.2.5 Kiln (Pembakaran)....................................................................
37
4.1.2.6 Finish Mill.................................................................................
38
4.1.2.7 Pengisian (Packer).....................................................................
39
4.2 Pengumpulan Data..........................................................................................
40
4.2.1 Data Breakdown Mesin Grinding Mill................................................
40
4.2.2 Data Biaya............................................................................................
43
4.3 Pengolahan Data.............................................................................................
45
4.3.1 Penentuan Distribusi Data dan Parameter Keandalan..........................
45
4.3.2 Menentukan Fungsi Padat Probabilitas................................................
47
4.3.3 Tingkat Keandalan Mesin Bucket Elevator.........................................
48
4.3.4 Perhitungan Laju Kerusakan................................................................
49
4.3.5 Perhitungan MTTF, MTTR, MTBF.....................................................
50
4.3.6 Ketersediaan (Availability)..................................................................
51
4.3.7 Perhitungan Biaya................................................................................
52
4.3.8 Perhitungan Perbandingan Sebelum dan Sesudah Perbaikan..............
55
BAB V ANALISA DAN PEMBAHASAN 5.1 Analisa Data....................................................................................................
57
5.1.1 Analisa Pembahasan untuk Penentuan Parameter...............................
57
5.1.2 Analisa Fungsi Padat Probabilitas Distribusi Weibul..........................
60
5.1.3 Analisa Fungsi Laju Kerusakan...........................................................
62
5.1.4 Perhitungan MTTF, MTTR, MTBF....................................................
63
5.1.5 Ketersediaan (Availability)..................................................................
64
5.1.6 Perhitungan Biaya...............................................................................
64
BAB VI KESIMPULAN DAN SARAN 6.1 Kesimpulan....................................................................................................
68
6.2 Saran..............................................................................................................
68
DAFTAR PUSTAKA..........................................................................................
71
DAFTAR GAMBAR
Gambar 2.2 Diagram alir dari pembagian perawatan............................................ 18 Gambar 2.3 Ilustrasi Ketersediaan.......................................................................... 22 Gambar 3.1 Flowchart Metodologi Penelitian........................................................ 26 Gambar 4.1 Batu Kapur.......................................................................................... 36 Gambar 4.2Tanah Liat............................................................................................ 36 Gambar 4.3 Pasir Besi............................................................................................ 36 Gambar 4.4 Pasir Silika.......................................................................................... 36 Gambar 4.5 Raw Mill............................................................................................. 37 Gambar 4.6 Silo Penyimpanan............................................................................... 37 Gambar 4.7 Proses Pembakaran............................................................................. 38 Gambar 4.8 Finish Mill........................................................................................... 39 Gambar 4.9 Proses Packing.................................................................................... 40 Gambar 4.16 Index of Fit........................................................................................ 47 Gambar 4.17 Grafik Fungsi Padat Probabilitas...................................................... 48 Gambar 4.18 Grafik Keandalan Mesin................................................................... 49 Gambar 4.19 Grafik Laju Kerusakan...................................................................... 50 Gambar 4.20 Laju operasi dan perbaikan............................................................... 51 Gambar 4.21 Grafik Total Biaya Perawatan........................................................... 53 Gambar 4.22 Grafik Keandalan Vs Biaya Perawatan............................................. 54 Gambar 5.1 Fungsi Padat Probabilitas.................................................................... 60 Gambar 5.2 Grafik Keandalan................................................................................ 61 Gambar 5.3 Grafik Laju Kerusakan........................................................................ 62 Gambar 5.4 Laju Operasi dan Perbaikan................................................................ 64
Gambar 5.5 Grafik Total Biaya Perawatan............................................................. 65 Gambar 5.6 Grafik Keandalan vs Biaya Perawatan Optimum............................... 66
DAFTAR TABEL
Tabel 2.1 Spesifikasi Mesin.....................................................................
25
Tabel 3.1 Distribusi Chi-Square............................................................................. 30 Tabel 4.1Data Mesin Kritis dan Tidak Kritis MesinGrinding Mill.....................
41
Tabel 4.2 Frekuensi Kerusakan.............................................................................. 42 Tabel 4.3 frekuensi penggantian komponenmesin Bucket elevator.....................
43
Tabel 4.6 Fixed Cost............................................................................................... 43 Tabel 4.7 Tabel Harga Komponen.......................................................................... 44 Tabel 4.8 Variabel Cost.......................................................................................... 44 Tabel 4.9 Distribusi................................................................................................ 45 Tabel 4.10 Hasil Uji Statistik................................................................................. 46 Tabel 4.11 Hasil Uji Statistik Lama Mesin menganggur....................................... 46 Tabel 4.12 Distribusi Weibull................................................................................ 46 Tabel 4.19 Hasil Perbandingan Total Biaya Awal dengan usulan Baru.............
55
Tabel 4.18 Perbandingan Sebelum dan Sesudah Perbaikan................................... 56 Tabel 5.1 Hasil Uji Distribusi Waktu Kerusakan................................................... 58 Tabel 5.2 Hasil Uji Statistik Lama Mesin Menganggur......................................... 59 Tabel 5.3 Parameter α dan β................................................................................... 60 Tabel 5.4 Keandalan Mesin Sebelum Perbaikan.................................................... 67 Tabel 5.5 Perbandingan Biaya Perbaikan............................................................... 67 Tabel 6.1 komponen kritis mesin bucket elevator................................................. 69
DAFTAR LAMPIRAN
Lampiran 1.................................................................................................
72
Lampiran 2.................................................................................................
73
Lampiran 3.................................................................................................
74
Lampiran 4.................................................................................................
75
Lampiran 5................................................................................................. Lampiran 6................................................................................................. Lampiran 7................................................................................................. Lampiran 8.................................................................................................
76 77 78 79 80
Lampiran 9.................................................................................................
81
Lampiran 10...............................................................................................
82
Lampiran 11...............................................................................................
83
Lampiran 12...............................................................................................
84
DAFTAR PUSTAKA
Benjamin Blanchard, 1991 ,“System Engineering and Analysis”. 4th Prentice Hall, Inc. B Syam, 2011. “ManajemenPerawatan dan Kontrol Komponen Screw press”. http://www.google.co.id/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2 &ved=0CCkQFjAB&url=http%3A%2F%2Frepository.usu.ac.id%2Fbitst ream%2F123456789%2F25071%2F3%2FChapter%2520II.pdf&ei=sr4v VfngDIOouwTs4IH4AQ&usg=AFQjCNHiDksP_yKRuqpnIkntug5Tu5O BqQ. Diakses 22 November 2014. Corder A.S Kusnul Hadi Ir. 1996. “Teknik Manajemen Pemeliharaan”. Erlangga Jakarta. Dhillon B.S. 2006. “Maintainability, Maintenance, and Reliability for Engineers”. Taylor& Francis, Boca Raton. Daryus Asyari, 2007. “Diklat Manajemen Pemeliharaan Mesin”. Universitas Darma Persada. Jakarta. Gasperz V,1992.“Analisis Sistem Terapan, Berdasarkan Pendekatan Teknik Industri”. Tarsito, Bandung. Heizer, Jay and Barry Render, 2001. “Operation Management, 7th edition”. Prentice-Hall Inc. New Jersey. R
Fitriyadi,
2011.
“Interval
Perawatan Mesin Pompa
Sentri
Fugal”.
http://repository.usu.ac.id/bitstream/123456789/25932/4/Chapter%20II.p df. Diakses 22 November 2014. JavadBarabady, 2005. “Improvement of System Availability UsingReliability and Maintainability
Analysis”.
Master
Thesis,
Lulea
University
ofTechnology. Lewis E.E ,1987.“Introduction to Reliability Enginering”.
Departement Of
Mechanical and Nuclear, Enginering Northwestern University, John Willeyand Sons, USA.
Priyanta, Dwi, 2000. “Keandalan dan Perawatan”. FTK ITS. Jurusan Teknik Perkapalan, Surabaya. Setiawan, F.D, 2008. “Perawatan Mekanikal Mesin Produksi”. Maximus, Yogyakarta. Smith,
Charles
o,
2001.
“Introduction
Design”.International student edition.
to
Realibility
Engineering
in
