USULAN PERBAIKAN FASILITAS KERJA PADA STASIUN PEMOTONGAN DENGAN METODE PAHL DAN BEITZ DI CV. MABAR KARYA UTAMA
TUGAS SARJANA Diajukan untuk Memenuhi Sebagian dari Syarat-syarat Penulisan Tugas Sarjana
oleh REVIYANTI DALIMUNTHE NIM. 080403210
PROGRAM PENDIDIKAN SARJANA EKSTENSI DEPARTEMEN TEKNIK INDUSTRI F A K U L T A S
T E K N I K
UNIVERSITAS SUMATERA UTARA MEDAN 2015
Universitas Sumatera Utara
Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis ucapkan kehadirat Tuhan Allah Yang Maha Esa yang telah memberikan rahmat dan karunia-Nya kepada penulis sehingga penulis dapat menyelesaikan TugasSarjanainidenganbaik. Tugas sarjanamerupakan salah satu syarat untuk mendapatkan gelar sarjana teknik di Departemen Teknik Industri, khususnya program studi reguler strata satu, Fakultas Teknik, Universitas Sumatera Utara. Adapun judul untuk tugas sarjana ini adalah “Usulan Perbaikan Fasilitas Kerja Pada Stasiun Pemotongan Dengan Metode Pahl dan Beitz di CV. MabarKaryaUtama”. Sebagai manusia yang tidak luput dari kesalahan, maka penulis menyadari masih banyak kekurangan dalam penulisan tugas sarjana ini. Oleh karena itu, penulis sangat mengharapkan saran dan masukan yang sifatnya membangun demi kesempurnaan laporan tugas sarjana ini. Semoga tugas sarjana ini dapat bermanfaat bagi penulis sendiri, perpustakaan Universitas Sumatera Utara, dan pembaca lainnya. Akhir kata, penulis mengharapkan agar tugas sarjana ini dapat memberikan manfaat bagi pembaca. Medan, September 2014
Penulis
Universitas Sumatera Utara
DAFTAR ISI
BAB
HALAMAN LEMBAR JUDUL .........................................................................................
i
LEMBAR PENGESAHAN ..........................................................................
ii
SERTIFIKAT EVALUASI DRAFT TUGAS SARJANA .........................
iii
KATA PENGANTAR ..................................................................................
iv
DAFTAR ISI .................................................................................................
viii
DAFTAR TABEL..........................................................................................
xiii
DAFTAR GAMBAR .....................................................................................
xv
DAFTAR LAMPIRAN .................................................................................
xvii
ABSTRAK .....................................................................................................
I
xviii
PENDAHULUAN.......................................................................................... ..... I-1
1.1. Latar Belakang ............................................................................
I-1
1.2. Rumusan Masalah .......................................................................
I-4
1.3. Tujuan dan Manfaat Penelitian ..................................................
I-4
1.3.1. Tujuan Penelitian ..............................................................
I-4
1.3.2. Manfaat Penelitian.............................................................
I-4
Universitas Sumatera Utara
DAFTAR ISI (Lanjutan)
BAB
II
III
HALAMAN
1.4. Batasan Masalah dan Asumsi ....................................................
I-5
1.5. Sistematika Penulisan Tugas Sarjana .........................................
I-6
GAMBARAN UMUM PERUSAHAAN ...........................................
II-1
2.1. Sejarah Umum Perusahaan ............................................................
II-1
2.2.
Ruang Lingkup Usaha ..........................................................................
II-2
2.3.
Struktur Organisasi ...............................................................................
II-4
2.4.
Pembagian Tugas dan Tanggung Jawab ..............................................
II-5
2.5.
Jumlah Tenaga Kerja dan Jam Kerja ...................................................
II-6
2.5.1. Jumlah Tenaga Kerja ..............................................................
II-6
2.5.2. Jam Kerja ................................................................................
II-6
LANDASAN TEORI .....................................................................................III-1
3.1. Ergonomi .....................................................................................
III-1
3.2. Antropometri ..............................................................................
III-2
3.2.1. Defenisi Anttropometri ...................................................
III-2
Universitas Sumatera Utara
DAFTAR ISI (Lanjutan)
BAB
HALAMAN
3.2.2. Faktor-faktor yang Mempengaruhi Pengukuran Antropometri ...................................................................
III-2
3.2.3. Aspek Antropometri dalam Perancangan Meja dan Kursi ................................................................
III-4
3.2.4. Aplikasi Antropometri dalam Perancangan Fasilitas Kerja .................................................................
III-7
3.2.5. Aplikasi Distribusi Normal dalam Penetapan Data Antropometri ........................................................... III-12 3.2.6. Pengujian Keseragaman Data ......................................... III-13 3.2.7. Uji Kecukupan Data ....................................................... III-15 3.2.8. Uji Kenormalan Data ...................................................... III-16 3.3. Keluhan Musculoskeletal ............................................................ III-16 3.4. Postur Kerja ................................................................................ III-20 3.5. Standard Nordic Quetionaire (SNQ) ......................................... III-21 3.6. Rapid Entire Body Assessment (REBA) .................................... III-23 3.7. Desain dan Redesain Peralatan Kerja ......................................... III-29 3.7.1. Desain ............................................................................. III-29 3.7.2. Redesain ......................................................................... III-31 3.8. Model Perancangan Menurut Pahl dan Beitz .............................. III-33
Universitas Sumatera Utara
DAFTAR ISI (Lanjutan)
BAB
HALAMAN
3.9. Konsep Desain ............................................................................ III-36
IV
BAB
V
METODOLOGI PENELITIAN ........................................................................IV1
4.1. Tempat dan Waktu Penelitian ....................................................
IV-1
4.2. Objek Penelitian ..........................................................................
IV-1
4.3. Jenis Penelitian ............................................................................
IV-1
4.4. Populasi dan Sample Penelitiaan ................................................
IV-1
HALAMAN
4.5. Kerangka Berfikir .......................................................................
IV-2
4.6. Instrumen Penelitian ...................................................................
IV-2
4.7. Sumber Data ................................................................................
IV-2
4.8. Metode Penelitian .......................................................................
IV-3
4.8.1. Metode Pengumpulan .....................................................
IV-3
4.8.2. Metode Pengolahan Data ................................................
IV-4
4.8.3. Metode Analisis Pemecahan Masalah ............................
IV-4
4.9. Kesimpulandan Saran ..................................................................
IV-5
PENGUMPULAN DAN PENGOLAHAN DATA ...................................... V-1
Universitas Sumatera Utara
DAFTAR ISI (Lanjutan)
BAB
HALAMAN
5.1. Pengumpulan Data ......................................................................
V-1
5.1.1. Proses danSituasiKerja .....................................................
V-1
5.1.2. Data HasilStandard Nordic Questionaire ........................
V-3
5.1.3. Data PosturKerja Operator ..............................................
V-5
5.1.4. Data Antropometri Operator ...........................................
V-7
5.2. Pengolahan Data 5.2.1. Data HasilStandard Nordic Questionaire .......................
V-9
5.2.2. Pengolahan Data PosturKerja........................................... V-10 5.3. Perhitungan Data Antropometri .................................................. V-14 5.3.1. Perhitungan Rata-rata dan Standard Deviasi ................... V-14 5.3.2. UjiKeseragaman Data ..................................................... V-15 5.3.3.
UjiKecukupan Data .......................................... V-23
5.3.4. UjiKenormalan Data ...................................................... V-25 5.3.5. PerhitunganPersentil ....................................................... V-25 5.4. DesainMejadanKursi Operator Berdasarkan Langkah-langkahPerancanganMenurutPahldanBeitz ................. V-26
VI
ANALISIS DAN PEMBAHASAN ...............................................................VI-1
6.1. Analisis Standard Nordic Questionnaire ....................................
VI-1
Universitas Sumatera Utara
DAFTAR ISI (Lanjutan)
BAB
HALAMAN
6.2. Analisis PosturTubuh Operator ..................................................
VI-1
6.3. AnalisisErgonomiDesainMejadanKursi ......................................
VI-3
6.4. Analisis Kondisi Kerja Aktual dan Usulan ................................
VI-4
6.5. Analisis Perbandingan Elemen Gerakan Aktual dengan Usulan .........................................................................................
VI-6
VII KESIMPULAN DAN SARAN .....................................................................VII-1 7.1.
Kesimpulan........................................................................................... VII-1
7.2.
Saran ..................................................................................................... VII-2
DAFTAR PUSTAKA LAMPIRAN
Universitas Sumatera Utara
DAFTAR GAMBAR
GAMBAR
HALAMAN
1.1. Operator PadaSaatMelakukanPemotongan ......................................
I-2
2.1. Struktur Organisasi CV. Mabar Karya Utama .................................
II-4
3.1. DimensiDasarPerancanganKursi .....................................................
III-4
3.2. DimensiDasarPerancanganMeja ......................................................
III-6
3.3. Antropometri Tubuh Manusiayang Diukur Dimensinya ................ III-10 3.4. Distribusi Normal dengan Data Antropometri Persenti95 ............... III-12 3.5. Standard Nordic Questionaire (SNQ).............................................. III-22 3.6. Postur Batang Tubuh REBA ........................................................... III-23 3.7. Postur Leher REBA ........................................................................ III-24 3.8. Postur Kaki REBA .......................................................................... III-24 3.9. Postur Lengan Atas REBA ............................................................. III-25 3.10. Postur Lengan Bawah REBA .......................................................... III-25 3.11. Postur Pergelangan Tangan REBA ................................................. III-26 3.12. REBA Assessments Worksheet ........................................................ III-29 3.13. Diagram Alir Proses PerancanganPahldanBeitz .............................. III-35 3.14. KonsepFolding ................................................................................. III-36 3.15. KonsepStacking................................................................................ III-37 3.16. KonsepPortable ............................................................................... III-37 3.17. KonsepKnock Down......................................................................... III-38
Universitas Sumatera Utara
DAFTAR GAMBAR (Lanjutan)
GAMBAR
HALAMAN
3.18. Konsep Adjustable ........................................................................... III-38 3.19. KonsepCombination ........................................................................ III-39 3.20. KonsepMenyusun ............................................................................ III-40 3.21. KonsepOnePiece .............................................................................. III-40 3.22. KonsepTwoPiece.............................................................................. III-41 3.23. Konsep Y ......................................................................................... III-41 3.24. KonsepWedding Stool ...................................................................... III-42 4.1. Flowchart Metodologi Penelitian ...................................................
IV-6
5.1. Mengukur Benda Kerja ...................................................................
V-1
5.2. Mengunci Benda Kerja ...................................................................
V-2
5.3. Menyalakan Mesin ..........................................................................
V-2
5.4. Memotong Benda Kerja ..................................................................
V-2
5.5. Mematikan Mesin ...........................................................................
V-3
5.6. Postur Kerja Mengukur ....................................................................
V-6
5.7. Postur Kerja Mengunci ....................................................................
V-6
5.8. Postur Kerja MenyalakanMesin.......................................................
V-6
5.9. Postur Kerja Memotong ...................................................................
V-7
5.10. Postur Kerja MematikanMesin ........................................................
V-7
5.11. Histogram Keluhan Operator ........................................................... V-10
Universitas Sumatera Utara
DAFTAR GAMBAR (Lanjutan)
GAMBAR
HALAMAN
5.12. Penilaian REBA KiriElemenGerakanMengukur Benda Kerja ..................................................................................... V-11 5.13. Penilaian REBA KananElemenGerakanMengukur Benda Kerja ..................................................................................... V-12 5.14. FungsiUtamaMeja ............................................................................ V-30 5.15. FungsiUtamaKursi ........................................................................... V-30 5.16. Konsep Awal Perancangan Meja TwoPiece dan Kursi Adjustable ........................................................................................ V-36 5.17. Konsep Akhir Perancangan Meja TwoPiece dan Kursi Adjustable ........................................................................................ V-37 5.18. Hasil Desain Meja Operator ............................................................. V-39 5.19. Kursi Operator ................................................................................. V-40 5.20. Troli Tampak Depan ........................................................................ V-41 6.1. Hasil Desain Meja dan Kursi Kerja .................................................
VI-3
6.2. Hasil Desain Meja dan Kursi Kerja Tampak Atas ...........................
VI-3
6.3. Hasil Desain Meja dan Kursi Kerja Tampak Belakang ...................
VI-4
6.4. Kondisi Kerja di Stasiun Pemotongan .............................................
VI-5
6.5. Elemen Kerja Aktual........................................................................
VI-7
6.6. Elemen Kerja Usulan .......................................................................
VI-7
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DAFTAR TABEL
TABEL
HALAMAN
2.1.
TenagaKerja CV. MabarKaryaUtama .............................................
II-6
2.2.
Jam KerjaKaryawan ........................................................................
II-7
3.1.
Jenis Persentil dan Perhitungan dalam Distribusi Normal .............. III-13
3.2.
SkorBatangTubuh REBA ................................................................ III-23
3.3.
SkorLeher REBA ............................................................................ III-24
3.4.
Skor Kaki REBA ............................................................................. III-24
3.5.
Tabel A (Penilaian Tubuh Bagian A) REBA .................................. III-25
3.6.
SkorLenganAtas REBA .................................................................. III-25
3.7.
SkorLenganBawah REBA .............................................................. III-26
3.8.
SkorPergelanganTangan REBA ...................................................... III-26
3.9.
Tabel B (Penilaian Tubuh Bagian B) REBA .................................. III-26
3.10. SkorBeban REBA ........................................................................... III-27 3.11. Skor CouplingREBA....................................................................... III-27 3.12. Skor C REBA .................................................................................. III-27 3.13. SkorAktivitas REBA ....................................................................... III-28 3.14. Nilai Level Tindakan REBA ........................................................... III-28 5.1.
Hasil Rekapitulasi Standard Nordic Questionnaire Operator ........
V-4
5.2.
Data HasilPengukuranAntropometri ...............................................
V-8
5.3.
Nilai Level Tindakan REBAKiri .................................................... V-12
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5.4.
Nilai Level Tindakan REBAKanan ................................................ V-13
5.5.
HasilPenilaianPosturKerja Operator ............................................... V-14
5.6.
PerhitunganUjiKeseragaman Data .................................................. V-17
5.7.
Data Out Of Control ........................................................................ V-18
5.8.
PerhitunganUjiKeseragaman Data Revisi I .................................... V-19
5.9.
Data Out of ControlRevisi I ............................................................ V-21
5.10. PerhitunganUjiKeseragaman Data Revisi II ................................... V-21 5.11. Data Out Of Control ........................................................................ V-24 5.12. UjiKecukupan Data ......................................................................... V-27 5.13. UjiKenormalan Data Dimensi ......................................................... V-25 5.14. PerhitunganPersentil ....................................................................... V-26 5.15. SpesifikasiMeja dan Kursi Operator Pemotongan .......................... V-27 5.16. Prinsip Pemecahan Masalah ............................................................ V-31 5.17. Tahap Pengembangan Konsep ........................................................ V-32 5.18. Formulir Pengisian .......................................................................... V-35 6.1.
Keterangan Gambar Kondisi Kerja di Stasiun Pemotongan ...........
VI-6
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