PENENTUAN INTERVAL PERAWATAN MESIN PADA KOMPONEN...

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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

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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

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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

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DAFTAR ISI

ISI HALAMAN

LEMBAR JUDUL................................................................................................

LEMBAR PENGESAHAN..................................................................................

SURAT PERNYATAAN KEASLIAN...............................................................

BERITA ACARA UJIAN TUGAS AKHIR........................................................

LEMBAR BIMBINGAN TUGAS AKHIR.........................................................

SURAT KETERANGAN PENELITIAN...........................................................

KATA PENGANTAR.........................................................................................

ABSTRAKSI.......................................................................................................

DAFTAR ISI........................................................................................................

DAFTAR TABEL................................................................................................

DAFTAR GAMBAR...........................................................................................

DAFTAR LAMPIRAN........................................................................................

BAB I PENDAHULUAN

1.1 Latar Belakang................................................................................................

1.2 Rumusan Masalah...........................................................................................

1.3 Tujuan Penelitian............................................................................................

1.4 Manfaat Penelitian..........................................................................................

1.5 Batasan Masalah dan Asumsi.........................................................................

BAB II LANDASAN TEORI

2.1 Deskripsi Keandalan.......................................................................................

2.1.1 Model Matematis Keandalan...............................................................

2.1.2 Fungsi Keandalan.................................................................................

2.1.3 Mean Time To Failure (MTTF)...........................................................

2.1.4 Fungsi laju Kerusakan (Hazard Fungtion)...........................................

2.1.5 Fungsi Distribusi Kerusakan................................................................

2.1.6 Mean Time Between Failure (MTBF).................................................

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2.1.7 Kurva Laju Kerusakan.........................................................................

2.2 Pengertian Perawatan......................................................................................

2.2.1 Tujuan Perawatan.................................................................................

2.2.2 Jenis-Jenis Perawatan...........................................................................

2.2.2.1 Perawatan Terencana..............................................................

2.2.2.2 Perawatan Tidak Terencana....................................................

2.3 Pengujian Kecocokan Data.............................................................................

2.3.1 Pengujian Chi Square (Goodness of Fit)..............................................

2.4 Ketersediaan (Availabilty)..............................................................................

2.5 Biaya Perawatan dan Perbaikan......................................................................

2.6 Penentuan Interval waktu Perawatan..............................................................

2.7 Mesin Bucket elevator....................................................................................

BAB III METODOLOGI PENELITIAN

3.1 Flow Chart......................................................................................................

3.2 Survey Perusahaan..........................................................................................

3.3 Perumusan Masalah dan tujuan Masalah........................................................

3.4 Tinjauan Pustaka.............................................................................................

3.5 Metode Pengumpulan data dan Pengolahan Data...........................................

3.6 Pengumpulan Data..........................................................................................

3.6.1 Biaya Kerusakan..................................................................................

3.6.2 Biaya Perawatan Terencana.................................................................

3.7 Pengolahan dan Analisa Data.........................................................................

3.8 Analisa Pembahasan.......................................................................................

3.9 Kesimpulan dan Saran....................................................................................

BAB IV PENGUMPULAN DAN PENGOLAHAN DATA

4.1 Tinjauan Perusahaan.......................................................................................

4.1.1 Profil Perusahaan.................................................................................

4.1.2 Proses Perusahaan................................................................................

4.1.2.1 Penyiapan Bahan Baku..............................................................

4.1.2.3 Crusher......................................................................................

4.1.2.4 Raw Mill....................................................................................

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4.1.2.5 Kiln (Pembakaran)....................................................................

4.1.2.6 Finish Mill.................................................................................

4.1.2.7 Pengisian (Packer).....................................................................

4.2 Pengumpulan Data..........................................................................................

4.2.1 Data Breakdown Mesin Grinding Mill................................................

4.2.2 Data Biaya............................................................................................

4.3 Pengolahan Data.............................................................................................

4.3.1 Penentuan Distribusi Data dan Parameter Keandalan..........................

4.3.2 Menentukan Fungsi Padat Probabilitas................................................

4.3.3 Tingkat Keandalan Mesin Bucket Elevator.........................................

4.3.4 Perhitungan Laju Kerusakan................................................................

4.3.5 Perhitungan MTTF, MTTR, MTBF.....................................................

4.3.6 Ketersediaan (Availability)..................................................................

4.3.7 Perhitungan Biaya................................................................................

4.3.8 Perhitungan Perbandingan Sebelum dan Sesudah Perbaikan..............

BAB V ANALISA DAN PEMBAHASAN

5.1 Analisa Data....................................................................................................

5.1.1 Analisa Pembahasan untuk Penentuan Parameter...............................

5.1.2 Analisa Fungsi Padat Probabilitas Distribusi Weibul..........................

5.1.3 Analisa Fungsi Laju Kerusakan...........................................................

5.1.4 Perhitungan MTTF, MTTR, MTBF....................................................

5.1.5 Ketersediaan (Availability)..................................................................

5.1.6 Perhitungan Biaya...............................................................................

BAB VI KESIMPULAN DAN SARAN

6.1 Kesimpulan....................................................................................................

6.2 Saran..............................................................................................................

DAFTAR PUSTAKA..........................................................................................

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DAFTAR GAMBAR

Gambar 2.2 Diagram alir dari pembagian perawatan............................................

Gambar 2.3 Ilustrasi Ketersediaan..........................................................................

Gambar 3.1 Flowchart Metodologi Penelitian........................................................

Gambar 4.1 Batu Kapur..........................................................................................

Gambar 4.2Tanah Liat............................................................................................

Gambar 4.3 Pasir Besi............................................................................................

Gambar 4.4 Pasir Silika..........................................................................................

Gambar 4.5 Raw Mill.............................................................................................

Gambar 4.6 Silo Penyimpanan...............................................................................

Gambar 4.7 Proses Pembakaran.............................................................................

Gambar 4.8 Finish Mill...........................................................................................

Gambar 4.9 Proses Packing....................................................................................

Gambar 4.16 Index of Fit........................................................................................

Gambar 4.17 Grafik Fungsi Padat Probabilitas......................................................

Gambar 4.18 Grafik Keandalan Mesin...................................................................

Gambar 4.19 Grafik Laju Kerusakan......................................................................

Gambar 4.20 Laju operasi dan perbaikan...............................................................

Gambar 4.21 Grafik Total Biaya Perawatan...........................................................

Gambar 4.22 Grafik Keandalan Vs Biaya Perawatan.............................................

Gambar 5.1 Fungsi Padat Probabilitas....................................................................

Gambar 5.2 Grafik Keandalan................................................................................

Gambar 5.3 Grafik Laju Kerusakan........................................................................

Gambar 5.4 Laju Operasi dan Perbaikan................................................................

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Gambar 5.5 Grafik Total Biaya Perawatan.............................................................

Gambar 5.6 Grafik Keandalan vs Biaya Perawatan Optimum...............................

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DAFTAR TABEL

Tabel 2.1 Spesifikasi Mesin.....................................................................

Tabel 3.1 Distribusi Chi-Square.............................................................................

Tabel 4.1Data Mesin Kritis dan Tidak Kritis MesinGrinding Mill.....................

Tabel 4.2 Frekuensi Kerusakan..............................................................................

Tabel 4.3 frekuensi penggantian komponenmesin Bucket elevator.....................

Tabel 4.6 Fixed Cost...............................................................................................

Tabel 4.7 Tabel Harga Komponen..........................................................................

Tabel 4.8 Variabel Cost..........................................................................................

Tabel 4.9 Distribusi................................................................................................

Tabel 4.10 Hasil Uji Statistik.................................................................................

Tabel 4.11 Hasil Uji Statistik Lama Mesin menganggur.......................................

Tabel 4.12 Distribusi Weibull................................................................................

Tabel 4.19 Hasil Perbandingan Total Biaya Awal dengan usulan Baru.............

Tabel 4.18 Perbandingan Sebelum dan Sesudah Perbaikan...................................

Tabel 5.1 Hasil Uji Distribusi Waktu Kerusakan...................................................

Tabel 5.2 Hasil Uji Statistik Lama Mesin Menganggur.........................................

Tabel 5.3 Parameter α dan β...................................................................................

Tabel 5.4 Keandalan Mesin Sebelum Perbaikan....................................................

Tabel 5.5 Perbandingan Biaya Perbaikan...............................................................

Tabel 6.1 komponen kritis mesin bucket elevator.................................................

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DAFTAR LAMPIRAN

Lampiran 1.................................................................................................

Lampiran 2.................................................................................................

Lampiran 3.................................................................................................

Lampiran 4.................................................................................................

Lampiran 5.................................................................................................

Lampiran 6.................................................................................................

Lampiran 7.................................................................................................

Lampiran 8.................................................................................................

Lampiran 9.................................................................................................

Lampiran 10...............................................................................................

Lampiran 11...............................................................................................

Lampiran 12...............................................................................................

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DAFTAR PUSTAKA

Benjamin Blanchard, 1991 ,“System Engineering and Analysis”. 4th Prentice

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B Syam, 2011. “ManajemenPerawatan dan Kontrol Komponen Screw press”.

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&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”.

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df. Diakses 22 November 2014.

JavadBarabady, 2005. “Improvement of System Availability UsingReliability and

Maintainability Analysis”. Master Thesis, Lulea University

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Lewis E.E ,1987.“Introduction to Reliability Enginering”. Departement Of

Mechanical and Nuclear, Enginering Northwestern University, John

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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 to Realibility Engineering in

Design”.International student edition.