Analisis Total Productive Maintenance pada Turntable Vibrating Compactor Guna Memperbaiki Kinerja Perusahaan PT. Indonesia Asahan Aluminium (Persero)
ANALISIS TOTAL PRODUCTIVE MAINTENANCE PADA
TURNTABLE VIBRRATING COMPACTOR GUNA
MEMPERBAIKI KINERJA PERUSAHAAN PT. INDONESIA
ASAHAN ALUMINIUM (Persero)
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi
Syarat Memperoleh Gelar Sarjana Teknik
Oleh :
TRABANASIA THERAH SITORUS
NIM : 110401078
DEPARTEMEN TEKNIK MESIN
FAKULTAS TEKNIK
UNIVERSITAS SUMATERA UTARA
MEDAN
2016
Universitas Sumatera Utara
ANALISIS TOTAL PRODUCTIVE MAINTENANCE PADA
TURNTABLE VIBRRATING COMPACTOR GUNA
MEMPERBAIKI KINERJA PERUSAHAAN PT. INDONESIA
ASAHAN ALUMINIUM (Persero)
DISUSUN OLEH :
TRABANASIA THERAH SITORUS
110401078
Medan, 18 Maret 2016
Penulis,
Trabanasia Therah Sitorus
NIM: 110401078
ii
Universitas Sumatera Utara
ABSTRAK
Total Productive Maintenance (TPM) merupakan ide Nakajima (1988) yang
menekankan pada pendayagunaan dan keterlibatan sumber daya manusia dan
sistem Preventive Maintenance untuk memaksimalkan efektifitas peralatan
dengan melibatkan semua departemen dan fungsional orgnisasi. Studi penerapan
TPM di Pabrik Anoda PT. INALUM (Persero) ini bertujuan untuk mengukur
efektifitas mesin Turntable Vibrating Compactor. Didalam analisis TPM dengan
menggunakan metode OEE ini ada terdapat enam penyebab kerugian yang disebut
dengan Six Big Losses yaitu diantaranya : Kerusakan peralatan (Breakdown
Losses), Persiapan peralatan (Set-up and Adjustment), Gangguan kecil dan waktu
nganggur (Idling and Minor Stoppages)Kecepatan rendah (Reduced Speed
Losses), Cacat produk dalam proses (Rework Losses), Hasil rendah (Yield/Scrap
losses). Kesimpulan yang didapat adalah nilai rata – rata OEE selama periode
April 2015 - Maret 2015adalah 63,65 % masih dibawah standar. Nilai
Idling/Minor Stoppages Losses 15,18% dengan total waktu 942,51 jam, hasil
Rework Losses0,02 % dengan total waktu 39,82jam, hasil Reduce Speed Losses
27,47% dengan total waktu 2120,69jam, hasil Breakdown Losses 7,75% dengan
total waktu 51,20 jam, hasil Setup and Adjustment Losses 0,81 % dengan total
waktu 57,31jam, hasil Yield/Scrap lossesdidapat 0.
Kata kunci : Overall Equipment Efectiveness, Availability, Breakdown Time, Rate of Quality
Product, Six Big Losses
i
Universitas Sumatera Utara
ABSTRACT
Total Productive Maintenance (TPM) is an idea Nakajima (1988), which
emphasizes the empowerment and involvement of human resources and
Preventive Maintenance System to maximize the effectiveness of the equipment by
involving all departments and functional society together. Study of the application
of TPM in Anode Plant PT. INALUM (Persero) is intended to measure the
effectiveness of Turntable Vibrating Compactor machine. In the analysis of TPM
using OEE there are six causes of loss of the so-called Six Big Losses of them:
Damage to equipment (Breakdown Losses), Preparation of equipment (Set-up and
Adjustment), disorders of the small and idle time (Idling and Minor Stoppages)
low speed (Speed Reduced losses), Defective products in the process (Rework
losses), lower results (Yield / Scrap losses). The conclusion is the value - average
OEE during the period April 2015 - March 2015 is 63.65% is below standard.
Value Idling / Minor Stoppages Losses 15.18% with a total time of 942.51 hours,
the results Rework Losses of 0.02% with a total time of 39.82 hours, the results
Reduce Speed Losses 27.47% with a total time of 2120.69 hours, the results
breakdown losses of 7.75% with a total time of 51.20 hours, the results Setup and
Adjustment losses of 0.81% with a total time of 57.31 hours, the results Yield /
Scrap losses obtained 0.
Keywords: Overall Equipment Efectiveness, Availability, Breakdown Time, Rate of Quality
Product, Six Big Losses
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Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis panjatkan ke hadirat Tuhan Yang Maha Esa
karena hanya atas berkat dan karunia-Nya penulis dapat mengerjakan dan
meyelesaikan skripsi ini dengan baik.
Skripsi ini merupakan salah satu syarat untuk menyelesaikan pendidikan
untuk mencapai gelar sarjana di Departemen Teknik Mesin Fakultas Teknik
Universitas Sumatera Utara. Adapun yang menjadi judul skripsi ini yaitu
“Analisis Total Productive Maintenance pada Turntable Vibrating Compactor
guna Memperbaiki Kinerja Perusahaan.”
Penulis berterima kasih kepada banyak pihak yang telah banyak membantu
penulis di berbagai hal dalam proses penyusunan skripsi ini. Oleh sebab itu,
penulis menyampaikan terima kasih kepada:
1. BapakIr. Alfian Hamsi, M.Sc., selaku Dosen Pembimbing yang telah
memberikan banyak bimbingan, arahan, dan masukan yang positif kepada
penulis selama penyusunan skripsi ini
2. Bapak, selaku Dosen Pembanding yang telah memberikan banyak saran
untuk perbaikan selama proses penyusunan skripsi ini.
3. Bapak Dr.Ing.Ir.Ikwansyah Isranuri, selaku Ketua Departemen Teknik
Mesin Fakultas Teknik USU.
4. Bapak/Ibu Staff Pengajar dan Pegawai di Departemen Teknik Mesin USU.
5. Kedua orang tua penulis Amson Harnold Sitorus dan Anny Juniar
Hutagaol, yang selalu memberikan doa dan dukungan berupa moral
maupun materi, yang selalu memberi semangat dan arahan dalam bersikap
selama proses penyusunan skripsi ini.
6. Teman sekelompok bimbingan penelitian, Febri Agustinus Ginting atas
kerjasama yang baik dalam proses bimbingan selama ini.
7. Orang tua dan keluarga besar penulis yang telah memberikan doa,
semangat, dan materil selama proses penyusunan skripsi ini.
8. Seluruh teman-teman penulis, baik teman satu angkatan 2011.
iii
Universitas Sumatera Utara
Penulis mengharapkan kritik dan saran yang membangun dari berbagai
pihak. Penulis juga mengharapkan skripsi ini dapat menjadi tambahan
pengetahuan bagi pembaca dan bermanfaat untuk kita semua. Terimakasih.
Medan, Juli 2016
Trabanasia Therah Sitorus
iv
Universitas Sumatera Utara
DAFTAR ISI
ABSTRAK ...................................................................................................... i
KATA PENGANTAR .................................................................................... iii
DAFTAR ISI ................................................................................................... v
DAFTAR GAMBAR ...................................................................................... viii
DAFTAR TABEL .......................................................................................... x
DAFTAR PERSAMAAN............................................................................... xii
DAFTAR NOTASI ......................................................................................... xiii
BAB I PENDAHULUAN...............................................................................1
1.1. Latar Belakang ............................................................................. 1
1.2. Permasalahan ................................................................................ 1
1.3. Tujuan Penelitian.......................................................................... 2
1.4. Batasan Masalah ........................................................................... 2
1.5. Manfaat Penelitian........................................................................ 2
1.6. Metodologi Penulisan ................................................................... 2
1.7. Sistematika Penulisan ................................................................... 3
BAB II GAMBARAN UMUM PERUSAHAAN DAN OBJEK
PENELITIAN................................................................... ................ 5
2.1. Alur Produksi PT. Inalum (persero) .............................................. 5
2.2.Mesin Vibrating Compactor........................................................... 13
2.2.1.Vibrating Compactor Secara Umum ........................................ 13
2.2.2.Vibrating Compactor yang Digunakan PT. Inalum (persero) .. 17
2.2.3.Komponen-komponen Utama Turntable Vibrating Compactor18
BAB II LANDASAN TEORI................................................................... ..... 24
3.1. Total Productive Maintenance (TPM) .......................................... 24
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Universitas Sumatera Utara
3.1.1.Definisi Total Productive Maintenance (TPM) ........................ 24
3.1.2.Keuntungan TPM ...................................................................... 25
3.2. Pengertian dan Tujuan Maintenance ............................................. 26
3.2.1.Pengertian Maintenance............................................................ 26
3.2.2. Tujuan Maintenance ................................................................ 27
3.3. Pembagian Maintenance ............................................................... 28
3.3.1.Pemeliharaan Terencana (Planned Maintenance) .................... 28
3.3.2.Pemeliharaan Tak Terencana (Unplanned Maintenance)......... 31
3.4.Perawatan Mandiri (Autonomous Maintenance) ............................ 31
3.5.OEE (Overall Equipment Effectiveness) ........................................ 33
3.6.Analisis Produktivitas : Six Big Losses (Enam Kerugian Besar) ... 38
BAB IV METODOLOGI PENELITIAN.....................................................40
4.1 Tempat dan Waktu Penelitian ........................................................ 40
4.1.1 Tempat Penelitan ...................................................................... 40
4.1.2 Waktu Penelitian ....................................................................... 40
4.2 Rancangan Penelitian ..................................................................... 40
4.3 Objek Penelitian ............................................................................. 40
4.4 Instrumen Penelitian ....................................................................... 40
4.5 Pelaksanaan Penelitian .................................................................. 40
4.6. Pengolahan Data ............................................................................ 41
4.7. Analisis Data dan Pemecahan Masalah ......................................... 44
BAB V PENGOLAHAN DAN ANALISA DATA......................................46
5.1. Pengumpulan Data ........................................................................ 46
5.1.1. Data waktu downtime .............................................................. 46
5.1.1. Planned Downtime ................................................................... 47
5.1.3. Data Waktu Setup .................................................................... 48
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Universitas Sumatera Utara
5.1.4. Data Waktu Produksi ............................................................... 49
5.2. Pengolahan Data ............................................................................ 51
5.2.1. Perhitungan Avalability ........................................................... 51
5.2.2.Perhitungan Performance Efficiency ........................................ 53
5.2.3.Perhitungan Rate Of Quality Product (RQP)............................ 55
5.2.4.Perhitungan Overall Equipment Effectiveness (OEE) .............. 56
5.2.5.Perhitungan Six Big Losses ....................................................... 58
5.3.Analisa Perhitungan ....................................................................... 68
5.3.1.Analisa perhitungan Overall Equipment Effectiveness (OEE) . 68
5.3.2.Analisa perhitungan OEE Six Big Losses ................................. 70
5.4.Analisa diagram sebab akibat (Fish Bone Diagram) ..................... 73
5.5.Usulan pemecahan masalah ........................................................... 75
5.5.1.Usulan penyelesaian masalah Six Big Losses ........................... 75
5.5.2.Penerapan Total Productive Maintenance (TPM) .................... 76
BAB VI KESIMPULAN DAN SARAN........................................................78
6.1. Kesimpulan.................................................................................... 78
6.2. Saran .............................................................................................. 79
DAFTAR PUSTAKA ..................................................................................... xiv
LAMPIRAN .................................................................................................... xv
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DAFTAR GAMBAR
Gambar 2.1 Single Sliding Table Vibrating Compactor ........................................14
Gambar 2.2. Tandem Sliding Table Vibrating Compactor ....................................15
Gambar 2.3 Triple Sliding Table Vibrating Compactor ........................................16
Gambar 2.4. Turntable Vibrating Compactor ........................................................17
Gambar 2.5. Turntable Vibrating Compactor di PT. Inalum (persero) ..................18
Gambar 2.6. Paste Spreading Device ....................................................................19
Gambar 2.7. HopperScale ......................................................................................19
Gambar 2.8. Vibrating Table With Unbalance Drive ............................................20
Gambar 2.9. Clamp Locking Device for Mould .....................................................21
Gambar 2.10. Pushing Device ................................................................................22
Gambar 2.11. Mould ..............................................................................................22
Gambar 2.12. Vacuum System................................................................................23
Gambar 3.1. Overall Equipment Effectiveness ......................................................33
Gambar 4.1. Tahapan proses pemecahan masalah .................................................44
Gambar 4.2 Diagram alir perhitungan Overall Equipment Effectiveness (OEE)...45
Gambar 5.1. Total Produksi (blok) mesin Turntable Vibrating
Compactor periode April 2015 – Maret 2016 ...................................51
Gambar 5.2. Diagram Availability mesin Turntable Vibrating Compactor...........53
Gambar 5.3. Diagram Performance Efficiency ......................................................55
Gambar 5.4. Diagram Rate of Quality Product......................................................56
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Universitas Sumatera Utara
Gambar 5.5. Diagram perolehan OEE mesin Turntable Vibrating Compactor
selama periode April 2015 – Maret 2016..........................................58
Gambar 5.6. Diagram Equipment Failure/Breakdown Lossperiode April 2015 Maret 2016 ........................................................................................60
Gambar 5.7. Diagram Setup and Adjustment losses periode
April 2015 - Maret 2016 ...................................................................62
Gambar 5.8. Diagram Idling and Minor Stoppages Lossesperiode
April 2015 - Maret 2016 ...................................................................64
Gambar 5.9. Diagram Reduce Speed LossesMesin Turntable
Vibrating Compactor ........................................................................65
Gambar 5.10. Diagram Rework losses untuk periode April 2015 –Maret 2016 ....67
Gambar 5.11. Grafik Perbandingan OEE Mesin Turntable Vibrating Compactor
periode April 2015-Maret 2016 dengan Standar JIPM (Japan
Institute Of Plant Maintenance) .......................................................69
Gambar 5.12. Diagram persentase Six Big Losses .................................................71
Gambar 5.13. Diagram Sebab Akibat (Fish Bone) ................................................73
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DAFTAR TABEL
Tabel 3.1. World Class OEE ..................................................................................37
Tabel 5.1. Data waktu kerusakan mesin Turntable Vibrating Compactor ............47
Tabel 5.2. Data waktu pemeliharaan mesin Turntable Vibrating Compactor .......48
Tabel 5.3. Data waktu Set Up mesin Turntable Vibrating Compactor ..................49
Tabel 5.4. Data Produksi Turntable Vibrating Compactor
periode April 2015 – Maret 2016 ..........................................................50
Table 5.5. Availability mesin Turntable Vibrating Compactor pada periode April
2015 – Maret 2016.................................................................................52
Tabel 5.6. Performance Efficiency periode April 2015 – Maret 2016 ...................54
Tabel 5.7 Perhitungan Rate of quality product periode April 2015 – Maret 2016 56
Tabel 5.8. Nilai Overall Equipment Effectiveness (OEE) mesin
Turntable Vibrating Compactor periode April 2015 – Maret 2016 ......57
Tabel 5.9. Equipment Failure/Breakdowns (EF) periode
April 2015-Maret 2016 ..........................................................................59
Tabel 5.10. Setup and Adjustment losses Periode April 2015-Maret 2016 ............61
Tabel 5.11. Idling and Minor Stoppages Losses untuk periode April 2015 - Maret
2015 .......................................................................................................63
Tabel 5.12. Reduce speed losses untuk periode April 2015 – Maret 2016 ............65
Tabel 5.13. Rework losses untuk periode April 2015 –Maret 2016 .......................67
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Universitas Sumatera Utara
Tabel 5.14. Persentase pencapaian mesin Turntable Vibrating Compactor periode
April 2015 – Maret 2016 .......................................................................69
Tabel 5.15. Persentase Faktor Six Big LossesMesin Turntable Vibrating
Compactor periode April 2015 – Maret 2016 .......................................70
Tabel 5.16. Perbandinganrata-rata Six Big LossesMesin Turntable Vibrating
Compactor .............................................................................................72
Tabel 5.17. Usulan penyelesaian masalah Six Big Losses .....................................75
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DAFTAR PERSAMAAN
Persamaan 3.1 : Overall Equipment Efectiveness (OEE).......................................34
Persamaan 3.2 : Availability (AV) .........................................................................34
Persamaan 3.3 : Loading Time ...............................................................................35
Persamaan 3.4 : Operation Time ............................................................................35
Persamaan 3.5 : Downtime .....................................................................................35
Persamaan 3.6 : Operation Speed Rate ..................................................................35
Persamaan 3.7 : Net Operation Rate ......................................................................36
Persamaan 3.8 : Performance Efficiency (PE) .......................................................36
Persamaan 3.9 : Rate of Quality Product (RQP)....................................................36
Persamaan 5.1 : Equipment Failure/Brealdowns (EF) ..........................................59
Persamaan 5.2 : Setup and Adjustment loss (SA) ..................................................61
Persamaan 5.3 : Idling and Minor Stoppages Losses (IMS) ..................................62
Persamaan 5.4 : Non Productive Time ...................................................................63
Persamaan 5.5 : Reduce Speed Losses(RS) ............................................................64
Persamaan 5.6 : Rework Loss (RL) ........................................................................66
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Universitas Sumatera Utara
DAFTAR NOTASI
KN
= KO-Kneader
SM
= Shaking Machine
PH
= Pre-Heater
AV
= Availability
PE
= Performance Efficiency
RQP
= Rate of Quality Product
OEE
= Overall Equipment Efectiveness
TPM
= Total Productive Maintenance
PM
= Planned Maintenance
EF
= Equipment Failure/Breakdown
SA
= Setup and Adjustment loss
IMS
= Idling and Minor Stoppages loss
RS
= Reduce Speed
RL
= Rework Loss
JIPM
= Japan Institute of Plant Maintenance
xiii
Universitas Sumatera Utara
TURNTABLE VIBRRATING COMPACTOR GUNA
MEMPERBAIKI KINERJA PERUSAHAAN PT. INDONESIA
ASAHAN ALUMINIUM (Persero)
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi
Syarat Memperoleh Gelar Sarjana Teknik
Oleh :
TRABANASIA THERAH SITORUS
NIM : 110401078
DEPARTEMEN TEKNIK MESIN
FAKULTAS TEKNIK
UNIVERSITAS SUMATERA UTARA
MEDAN
2016
Universitas Sumatera Utara
ANALISIS TOTAL PRODUCTIVE MAINTENANCE PADA
TURNTABLE VIBRRATING COMPACTOR GUNA
MEMPERBAIKI KINERJA PERUSAHAAN PT. INDONESIA
ASAHAN ALUMINIUM (Persero)
DISUSUN OLEH :
TRABANASIA THERAH SITORUS
110401078
Medan, 18 Maret 2016
Penulis,
Trabanasia Therah Sitorus
NIM: 110401078
ii
Universitas Sumatera Utara
ABSTRAK
Total Productive Maintenance (TPM) merupakan ide Nakajima (1988) yang
menekankan pada pendayagunaan dan keterlibatan sumber daya manusia dan
sistem Preventive Maintenance untuk memaksimalkan efektifitas peralatan
dengan melibatkan semua departemen dan fungsional orgnisasi. Studi penerapan
TPM di Pabrik Anoda PT. INALUM (Persero) ini bertujuan untuk mengukur
efektifitas mesin Turntable Vibrating Compactor. Didalam analisis TPM dengan
menggunakan metode OEE ini ada terdapat enam penyebab kerugian yang disebut
dengan Six Big Losses yaitu diantaranya : Kerusakan peralatan (Breakdown
Losses), Persiapan peralatan (Set-up and Adjustment), Gangguan kecil dan waktu
nganggur (Idling and Minor Stoppages)Kecepatan rendah (Reduced Speed
Losses), Cacat produk dalam proses (Rework Losses), Hasil rendah (Yield/Scrap
losses). Kesimpulan yang didapat adalah nilai rata – rata OEE selama periode
April 2015 - Maret 2015adalah 63,65 % masih dibawah standar. Nilai
Idling/Minor Stoppages Losses 15,18% dengan total waktu 942,51 jam, hasil
Rework Losses0,02 % dengan total waktu 39,82jam, hasil Reduce Speed Losses
27,47% dengan total waktu 2120,69jam, hasil Breakdown Losses 7,75% dengan
total waktu 51,20 jam, hasil Setup and Adjustment Losses 0,81 % dengan total
waktu 57,31jam, hasil Yield/Scrap lossesdidapat 0.
Kata kunci : Overall Equipment Efectiveness, Availability, Breakdown Time, Rate of Quality
Product, Six Big Losses
i
Universitas Sumatera Utara
ABSTRACT
Total Productive Maintenance (TPM) is an idea Nakajima (1988), which
emphasizes the empowerment and involvement of human resources and
Preventive Maintenance System to maximize the effectiveness of the equipment by
involving all departments and functional society together. Study of the application
of TPM in Anode Plant PT. INALUM (Persero) is intended to measure the
effectiveness of Turntable Vibrating Compactor machine. In the analysis of TPM
using OEE there are six causes of loss of the so-called Six Big Losses of them:
Damage to equipment (Breakdown Losses), Preparation of equipment (Set-up and
Adjustment), disorders of the small and idle time (Idling and Minor Stoppages)
low speed (Speed Reduced losses), Defective products in the process (Rework
losses), lower results (Yield / Scrap losses). The conclusion is the value - average
OEE during the period April 2015 - March 2015 is 63.65% is below standard.
Value Idling / Minor Stoppages Losses 15.18% with a total time of 942.51 hours,
the results Rework Losses of 0.02% with a total time of 39.82 hours, the results
Reduce Speed Losses 27.47% with a total time of 2120.69 hours, the results
breakdown losses of 7.75% with a total time of 51.20 hours, the results Setup and
Adjustment losses of 0.81% with a total time of 57.31 hours, the results Yield /
Scrap losses obtained 0.
Keywords: Overall Equipment Efectiveness, Availability, Breakdown Time, Rate of Quality
Product, Six Big Losses
ii
Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis panjatkan ke hadirat Tuhan Yang Maha Esa
karena hanya atas berkat dan karunia-Nya penulis dapat mengerjakan dan
meyelesaikan skripsi ini dengan baik.
Skripsi ini merupakan salah satu syarat untuk menyelesaikan pendidikan
untuk mencapai gelar sarjana di Departemen Teknik Mesin Fakultas Teknik
Universitas Sumatera Utara. Adapun yang menjadi judul skripsi ini yaitu
“Analisis Total Productive Maintenance pada Turntable Vibrating Compactor
guna Memperbaiki Kinerja Perusahaan.”
Penulis berterima kasih kepada banyak pihak yang telah banyak membantu
penulis di berbagai hal dalam proses penyusunan skripsi ini. Oleh sebab itu,
penulis menyampaikan terima kasih kepada:
1. BapakIr. Alfian Hamsi, M.Sc., selaku Dosen Pembimbing yang telah
memberikan banyak bimbingan, arahan, dan masukan yang positif kepada
penulis selama penyusunan skripsi ini
2. Bapak, selaku Dosen Pembanding yang telah memberikan banyak saran
untuk perbaikan selama proses penyusunan skripsi ini.
3. Bapak Dr.Ing.Ir.Ikwansyah Isranuri, selaku Ketua Departemen Teknik
Mesin Fakultas Teknik USU.
4. Bapak/Ibu Staff Pengajar dan Pegawai di Departemen Teknik Mesin USU.
5. Kedua orang tua penulis Amson Harnold Sitorus dan Anny Juniar
Hutagaol, yang selalu memberikan doa dan dukungan berupa moral
maupun materi, yang selalu memberi semangat dan arahan dalam bersikap
selama proses penyusunan skripsi ini.
6. Teman sekelompok bimbingan penelitian, Febri Agustinus Ginting atas
kerjasama yang baik dalam proses bimbingan selama ini.
7. Orang tua dan keluarga besar penulis yang telah memberikan doa,
semangat, dan materil selama proses penyusunan skripsi ini.
8. Seluruh teman-teman penulis, baik teman satu angkatan 2011.
iii
Universitas Sumatera Utara
Penulis mengharapkan kritik dan saran yang membangun dari berbagai
pihak. Penulis juga mengharapkan skripsi ini dapat menjadi tambahan
pengetahuan bagi pembaca dan bermanfaat untuk kita semua. Terimakasih.
Medan, Juli 2016
Trabanasia Therah Sitorus
iv
Universitas Sumatera Utara
DAFTAR ISI
ABSTRAK ...................................................................................................... i
KATA PENGANTAR .................................................................................... iii
DAFTAR ISI ................................................................................................... v
DAFTAR GAMBAR ...................................................................................... viii
DAFTAR TABEL .......................................................................................... x
DAFTAR PERSAMAAN............................................................................... xii
DAFTAR NOTASI ......................................................................................... xiii
BAB I PENDAHULUAN...............................................................................1
1.1. Latar Belakang ............................................................................. 1
1.2. Permasalahan ................................................................................ 1
1.3. Tujuan Penelitian.......................................................................... 2
1.4. Batasan Masalah ........................................................................... 2
1.5. Manfaat Penelitian........................................................................ 2
1.6. Metodologi Penulisan ................................................................... 2
1.7. Sistematika Penulisan ................................................................... 3
BAB II GAMBARAN UMUM PERUSAHAAN DAN OBJEK
PENELITIAN................................................................... ................ 5
2.1. Alur Produksi PT. Inalum (persero) .............................................. 5
2.2.Mesin Vibrating Compactor........................................................... 13
2.2.1.Vibrating Compactor Secara Umum ........................................ 13
2.2.2.Vibrating Compactor yang Digunakan PT. Inalum (persero) .. 17
2.2.3.Komponen-komponen Utama Turntable Vibrating Compactor18
BAB II LANDASAN TEORI................................................................... ..... 24
3.1. Total Productive Maintenance (TPM) .......................................... 24
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Universitas Sumatera Utara
3.1.1.Definisi Total Productive Maintenance (TPM) ........................ 24
3.1.2.Keuntungan TPM ...................................................................... 25
3.2. Pengertian dan Tujuan Maintenance ............................................. 26
3.2.1.Pengertian Maintenance............................................................ 26
3.2.2. Tujuan Maintenance ................................................................ 27
3.3. Pembagian Maintenance ............................................................... 28
3.3.1.Pemeliharaan Terencana (Planned Maintenance) .................... 28
3.3.2.Pemeliharaan Tak Terencana (Unplanned Maintenance)......... 31
3.4.Perawatan Mandiri (Autonomous Maintenance) ............................ 31
3.5.OEE (Overall Equipment Effectiveness) ........................................ 33
3.6.Analisis Produktivitas : Six Big Losses (Enam Kerugian Besar) ... 38
BAB IV METODOLOGI PENELITIAN.....................................................40
4.1 Tempat dan Waktu Penelitian ........................................................ 40
4.1.1 Tempat Penelitan ...................................................................... 40
4.1.2 Waktu Penelitian ....................................................................... 40
4.2 Rancangan Penelitian ..................................................................... 40
4.3 Objek Penelitian ............................................................................. 40
4.4 Instrumen Penelitian ....................................................................... 40
4.5 Pelaksanaan Penelitian .................................................................. 40
4.6. Pengolahan Data ............................................................................ 41
4.7. Analisis Data dan Pemecahan Masalah ......................................... 44
BAB V PENGOLAHAN DAN ANALISA DATA......................................46
5.1. Pengumpulan Data ........................................................................ 46
5.1.1. Data waktu downtime .............................................................. 46
5.1.1. Planned Downtime ................................................................... 47
5.1.3. Data Waktu Setup .................................................................... 48
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5.1.4. Data Waktu Produksi ............................................................... 49
5.2. Pengolahan Data ............................................................................ 51
5.2.1. Perhitungan Avalability ........................................................... 51
5.2.2.Perhitungan Performance Efficiency ........................................ 53
5.2.3.Perhitungan Rate Of Quality Product (RQP)............................ 55
5.2.4.Perhitungan Overall Equipment Effectiveness (OEE) .............. 56
5.2.5.Perhitungan Six Big Losses ....................................................... 58
5.3.Analisa Perhitungan ....................................................................... 68
5.3.1.Analisa perhitungan Overall Equipment Effectiveness (OEE) . 68
5.3.2.Analisa perhitungan OEE Six Big Losses ................................. 70
5.4.Analisa diagram sebab akibat (Fish Bone Diagram) ..................... 73
5.5.Usulan pemecahan masalah ........................................................... 75
5.5.1.Usulan penyelesaian masalah Six Big Losses ........................... 75
5.5.2.Penerapan Total Productive Maintenance (TPM) .................... 76
BAB VI KESIMPULAN DAN SARAN........................................................78
6.1. Kesimpulan.................................................................................... 78
6.2. Saran .............................................................................................. 79
DAFTAR PUSTAKA ..................................................................................... xiv
LAMPIRAN .................................................................................................... xv
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DAFTAR GAMBAR
Gambar 2.1 Single Sliding Table Vibrating Compactor ........................................14
Gambar 2.2. Tandem Sliding Table Vibrating Compactor ....................................15
Gambar 2.3 Triple Sliding Table Vibrating Compactor ........................................16
Gambar 2.4. Turntable Vibrating Compactor ........................................................17
Gambar 2.5. Turntable Vibrating Compactor di PT. Inalum (persero) ..................18
Gambar 2.6. Paste Spreading Device ....................................................................19
Gambar 2.7. HopperScale ......................................................................................19
Gambar 2.8. Vibrating Table With Unbalance Drive ............................................20
Gambar 2.9. Clamp Locking Device for Mould .....................................................21
Gambar 2.10. Pushing Device ................................................................................22
Gambar 2.11. Mould ..............................................................................................22
Gambar 2.12. Vacuum System................................................................................23
Gambar 3.1. Overall Equipment Effectiveness ......................................................33
Gambar 4.1. Tahapan proses pemecahan masalah .................................................44
Gambar 4.2 Diagram alir perhitungan Overall Equipment Effectiveness (OEE)...45
Gambar 5.1. Total Produksi (blok) mesin Turntable Vibrating
Compactor periode April 2015 – Maret 2016 ...................................51
Gambar 5.2. Diagram Availability mesin Turntable Vibrating Compactor...........53
Gambar 5.3. Diagram Performance Efficiency ......................................................55
Gambar 5.4. Diagram Rate of Quality Product......................................................56
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Gambar 5.5. Diagram perolehan OEE mesin Turntable Vibrating Compactor
selama periode April 2015 – Maret 2016..........................................58
Gambar 5.6. Diagram Equipment Failure/Breakdown Lossperiode April 2015 Maret 2016 ........................................................................................60
Gambar 5.7. Diagram Setup and Adjustment losses periode
April 2015 - Maret 2016 ...................................................................62
Gambar 5.8. Diagram Idling and Minor Stoppages Lossesperiode
April 2015 - Maret 2016 ...................................................................64
Gambar 5.9. Diagram Reduce Speed LossesMesin Turntable
Vibrating Compactor ........................................................................65
Gambar 5.10. Diagram Rework losses untuk periode April 2015 –Maret 2016 ....67
Gambar 5.11. Grafik Perbandingan OEE Mesin Turntable Vibrating Compactor
periode April 2015-Maret 2016 dengan Standar JIPM (Japan
Institute Of Plant Maintenance) .......................................................69
Gambar 5.12. Diagram persentase Six Big Losses .................................................71
Gambar 5.13. Diagram Sebab Akibat (Fish Bone) ................................................73
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DAFTAR TABEL
Tabel 3.1. World Class OEE ..................................................................................37
Tabel 5.1. Data waktu kerusakan mesin Turntable Vibrating Compactor ............47
Tabel 5.2. Data waktu pemeliharaan mesin Turntable Vibrating Compactor .......48
Tabel 5.3. Data waktu Set Up mesin Turntable Vibrating Compactor ..................49
Tabel 5.4. Data Produksi Turntable Vibrating Compactor
periode April 2015 – Maret 2016 ..........................................................50
Table 5.5. Availability mesin Turntable Vibrating Compactor pada periode April
2015 – Maret 2016.................................................................................52
Tabel 5.6. Performance Efficiency periode April 2015 – Maret 2016 ...................54
Tabel 5.7 Perhitungan Rate of quality product periode April 2015 – Maret 2016 56
Tabel 5.8. Nilai Overall Equipment Effectiveness (OEE) mesin
Turntable Vibrating Compactor periode April 2015 – Maret 2016 ......57
Tabel 5.9. Equipment Failure/Breakdowns (EF) periode
April 2015-Maret 2016 ..........................................................................59
Tabel 5.10. Setup and Adjustment losses Periode April 2015-Maret 2016 ............61
Tabel 5.11. Idling and Minor Stoppages Losses untuk periode April 2015 - Maret
2015 .......................................................................................................63
Tabel 5.12. Reduce speed losses untuk periode April 2015 – Maret 2016 ............65
Tabel 5.13. Rework losses untuk periode April 2015 –Maret 2016 .......................67
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Tabel 5.14. Persentase pencapaian mesin Turntable Vibrating Compactor periode
April 2015 – Maret 2016 .......................................................................69
Tabel 5.15. Persentase Faktor Six Big LossesMesin Turntable Vibrating
Compactor periode April 2015 – Maret 2016 .......................................70
Tabel 5.16. Perbandinganrata-rata Six Big LossesMesin Turntable Vibrating
Compactor .............................................................................................72
Tabel 5.17. Usulan penyelesaian masalah Six Big Losses .....................................75
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DAFTAR PERSAMAAN
Persamaan 3.1 : Overall Equipment Efectiveness (OEE).......................................34
Persamaan 3.2 : Availability (AV) .........................................................................34
Persamaan 3.3 : Loading Time ...............................................................................35
Persamaan 3.4 : Operation Time ............................................................................35
Persamaan 3.5 : Downtime .....................................................................................35
Persamaan 3.6 : Operation Speed Rate ..................................................................35
Persamaan 3.7 : Net Operation Rate ......................................................................36
Persamaan 3.8 : Performance Efficiency (PE) .......................................................36
Persamaan 3.9 : Rate of Quality Product (RQP)....................................................36
Persamaan 5.1 : Equipment Failure/Brealdowns (EF) ..........................................59
Persamaan 5.2 : Setup and Adjustment loss (SA) ..................................................61
Persamaan 5.3 : Idling and Minor Stoppages Losses (IMS) ..................................62
Persamaan 5.4 : Non Productive Time ...................................................................63
Persamaan 5.5 : Reduce Speed Losses(RS) ............................................................64
Persamaan 5.6 : Rework Loss (RL) ........................................................................66
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DAFTAR NOTASI
KN
= KO-Kneader
SM
= Shaking Machine
PH
= Pre-Heater
AV
= Availability
PE
= Performance Efficiency
RQP
= Rate of Quality Product
OEE
= Overall Equipment Efectiveness
TPM
= Total Productive Maintenance
PM
= Planned Maintenance
EF
= Equipment Failure/Breakdown
SA
= Setup and Adjustment loss
IMS
= Idling and Minor Stoppages loss
RS
= Reduce Speed
RL
= Rework Loss
JIPM
= Japan Institute of Plant Maintenance
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