Usulan Perbaikan Fasilitas Kerja Pada Stasiun Pemotongan Dengan Metode Pahl dan Beitz di CV. MabarKaryaUtama.

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 D E P A R T E M E N T E K N I K I N D U S T R I

F A K U L T A S T E K N I K

UNIVERSITAS SUMATERA UTARA MEDAN

  2015

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

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 ..................................................................................................... xviii

  I 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

  DAFTAR ISI (Lanjutan) BAB HALAMAN

  1.4. Batasan Masalah dan Asumsi .................................................... I-5

  1.5. Sistematika Penulisan Tugas Sarjana ......................................... I-6 II 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

  III LANDASAN TEORI ..................................................................................... III-1

  3.1. Ergonomi ..................................................................................... III-1

  3.2. Antropometri .............................................................................. III-2

  3.2.1. Defenisi Anttropometri ................................................... III-2

  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

  DAFTAR ISI (Lanjutan) BAB HALAMAN

  3.9. Konsep Desain ............................................................................ III-36

  IV 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

  BAB 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

  V PENGUMPULAN DAN PENGOLAHAN DATA ...................................... V-1

  DAFTAR ISI (Lanjutan) BAB HALAMAN

  5.3.1. Perhitungan Rata-rata dan Standard Deviasi ................... V-14

  VI ANALISIS DAN PEMBAHASAN ............................................................... VI-1

  5.4. DesainMejadanKursi Operator Berdasarkan Langkah-langkahPerancanganMenurutPahldanBeitz ................. V-26

  5.3.5. PerhitunganPersentil ....................................................... V-25

  5.3.4. UjiKenormalan Data ...................................................... V-25

  5.3.3. UjiKecukupan Data .......................................... V-23

  5.3.2. UjiKeseragaman Data ..................................................... V-15

  5.3. Perhitungan Data Antropometri .................................................. V-14

  5.1. Pengumpulan Data ...................................................................... V-1

  5.2.2. Pengolahan Data PosturKerja........................................... V-10

  5.2.1. Data HasilStandard Nordic Questionaire ....................... V-9

  5.2. Pengolahan Data

  5.1.4. Data Antropometri Operator ........................................... V-7

  5.1.3. Data PosturKerja Operator .............................................. V-5

  5.1.2. Data HasilStandard Nordic Questionaire ........................ V-3

  5.1.1. Proses danSituasiKerja ..................................................... V-1

  6.1. Analisis Standard Nordic Questionnaire .................................... VI-1

  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

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

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

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

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

  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