Analisa pada Pembangkit Listrik Tenaga Gas GT 2.1 dengan Metode Overall Equipment Effectiveness (OEE) untuk Memetakan Efisiensi Produksi di PT. PLN SECANANG – BELAWAN
ANALISA PADA PEMBANGKIT LISTRIK TENAGA GAS GT 2.1
DENGAN METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE)
UNTUK MEMETAKAN EFISIENSI PRODUKSI
DI PT. PLN SECANANG – BELAWAN
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi
Syarat Memperoleh Gelar Sarjana Teknik
MAWARDY NP HUTASOIT
110401059
DEPARTEMEN TEKNIK MESIN
FAKULTAS TEKNIK
UNIVERSITAS SUMATERA UTARA
MEDAN
2016
Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis panjatkan kepada Tuhan Yang Maha Esa, atas
berkat dan karunia-Nya maka skripsi ini dapat diselesaikan dengan baik.
Skripsi yang berjudul " Analisa pada Pembangkit Listrik Tenaga Gas GT 2.1
dengan Metode Overall Equipment Effectiveness (OEE) untuk Memetakan
Efisiensi Produksi Di PT. PLN SECANANG – BELAWAN " ini penulis susun
untuk memenuhi persyaratan kurikulum Sarjana Strata-1 (S-1) pada Departemen
Teknik Mesin, Fakultas Teknik, Universitas Sumatera Utara.
Penulis mengucapkan rasa terima kasih yang sebesar-besarnya atas semua
bantuan yang telah diberikan, baik secara langsung maupun tidak langsung selama
penyusunan tugas akhir ini hingga selesai. Secara khusus rasa terimakasih tersebut
penulis sampaikan kepada:
1. Kedua orang tua Ayahanda Drs. S. Hutasoit, Ibunda M. Lumbantoruan B.A
dan keluarga besar Hutasoit atas doa, kasih sayang, pengorbanan, tanggung
jawab yang selalu menyertai penulis, dan memberikan penulis semangat yang
luar biasa sehingga penulis dapat menyelesaikan skripsi ini.
2. Bapak Dr. Ir. M.Sabri, MT selaku dosen pembimbing yang telah memberikan
bimbingan dan dorongan dalam penyusunan tugas akhir ini.
3. Bapak Dr. Ing. Ir Ikhwansyah Isranuri selaku Ketua Jurusan Departemen
Teknik Mesin, Fakultas Teknik, Universitas Sumatera Utara.
4. Ir. Syahril Gultom, MT selaku Sekretaris Departemen Teknik Mesin, Fakultas
Teknik, Universitas Sumatera Utara.
5. Bapak Ir. Tugiman, MT selaku Koordinator Skripsi Departemen Teknik Mesin,
Fakultas Teknik, Universitas Sumatera Utara.
6. Seluruh Dosen dan seluruh Pegawai Administrasi Departemen Teknik Mesin,
juga kepada Staf Fakultas Teknik, Universitas Sumatera Utara, atas ilmu,
bimbingan dan bantuannya hingga penulis selesai menyusun tugas akhir ini.
7. Rekan-rekan Stambuk 2011, Penggo, link kupi, PK2L, Olu, Tim Horas
Universitas Sumatera Utara yang juga telah banyak membantu penulis dan
memberi semangat.
i
Universitas Sumatera Utara
Penulis menyadari bahwa tugas akhir ini jauh dari kata sempurna, baik
dari segi materi maupun penyajiannya. Untuk itu saran dan kritik yang
membangun sangat diharapkan dalam penyempurnaan tugas akhir ini. Terakhir
penulis berharap, semoga tugas akhir ini dapat memberikan hal yang bermanfaat
dan menambah wawasan bagi pembaca dan khususnya bagi penulis juga.
Medan,
November 2016
Penulis,
Mawardy NP Hutasoit
NIM : 110401059
ii
Universitas Sumatera Utara
ABSTRAK
PT. Perusahaan Listrik Negara (PLN) Secanang – Belawan, merupakan
perusahaan yang bergerak di bidang pelayanan terhadap pelanggan dan listrik.
Energi listrik merupakan sumber daya yang sangat dibutuhkan dalam rangka
meningkatkan kesejahteraan masyarakat, yang dalam prosesnya tidak terlepas dari
problem efektivitas paralatan atau mesin. Penerapan metode Failure Mode And
Effect Analisys (FMEA) merupakan suatu prosedur untuk mengidentifikasi
kegagalan
produk
yang
terjadi
sedangkan
metode
Overall
Equipment
Effectivenees (OEE) merupakan suatu pengukuran efektivitas pemakaian suatu
mesin/peralatan dengan menghitung ketersediaan mesin, performansi dan kualitas
produk yang dihasilkan. Perhitungan six big losses dilakukan untuk mengetahui
kerugian yang menyebabkan rendahnya nilai OEE. Total Productive Maintenance
merupakan suatu prinsip manajemen untuk meningkatkan produktivitas dan
efisiensi produksi perusahaan dengan menggunakan mesin secara efektif.
Penelitian ini mengarah pada pengukuran nilai OEE dalam satu lini produksi.
Berdasarkan perhitungan nilai OEE pada Turbin Gas GT 2.1 selama bulan Januari
2015 – Desember 2015 diperoleh nilai Availability = 99,86% kondisi ini dianggap
sempurna sebesar 100%, Performance efesiensi = 84,53% kondisi ini dianggap
kelas dunia sebesar 85%, Quality of rate = 99,67% kondisi ini dianggap sempurna
sebesar 100%, Dan nilai hasil OEE = 84,15% kondisi ini dianggap kelas dunia
skor yang cocok untuk dijadikan goal jangka panjang.
Kata kunci ; FMEA, OEE, Availability, Performance efesiensi, Quality of rate
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Universitas Sumatera Utara
ABSTRACT
PT. State Electricity Company (PLN) Secanang - Belawan, is a company
engaged in the field of customer service and electricity. Electrical energy is a
resource that is needed in order to improve the welfare of society, which is in the
process can not be separated from the problem of effectiveness paralatan or
machine. Application of the method Failure Mode And Effect Analisys (FMEA) is
a procedure to identify product failures that occurred while the method
Effectivenees Overall Equipment (OEE) is a measurement of the effectiveness of
the use of a machine / equipment by calculating machine availability, performance
and quality of the product. Six big losses calculation is performed to determine
damages to the low value of OEE. Total Productive Maintenance is a principle of
management to increase productivity and production efficiency for companies
using the machine effectively. This research led to the measurement of values
OEE in a single production line. Based on the calculation of OEE in Gas Turbine
GT 2.1 during the month of January 2015 - December 2015 obtained value
Availability = 99.86% This condition is considered perfect by 100%, Performance
efficiency = 84.53% This condition is considered world class by 85%, Quality of
rate = 99.67% is considered perfect condition at 100%, and the value of the OEE
= 84.15% is considered a world-class condition score is suitable to serve as goal. a
long-term.
Keywords ; FMEA,OEE, Availability, Performance efficiency, Quality of rate
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Universitas Sumatera Utara
DAFTAR ISI
KATA PENGANTAR ........................................................................................ i
ABSTRAK ........................................................................................................iii
DAFTAR ISI ...................................................................................................... v
DAFTAR GAMBAR ......................................................................................viii
DAFTAR TABEL ............................................................................................ ix
BAB I PENDAHULUAN .................................................................................. 1
1.1. ...................................................................................................... La
tar Belakang ............................................................................................ 1
1.2. ...................................................................................................... Po
kok Permasalahan.................................................................................... 2
1.3. ...................................................................................................... Ru
musan Masalah ........................................................................................ 3
1.4. ...................................................................................................... Ba
tasan Masalah Penelitian ......................................................................... 3
1.5. ...................................................................................................... As
umsi – Asumsi ......................................................................................... 3
1.6. ...................................................................................................... Tu
juan Penelitian ......................................................................................... 3
1.7. ...................................................................................................... M
anfaat Penulisan ...................................................................................... 4
1.8. ...................................................................................................... Si
stematika Penulisan Skripsi .................................................................... 4
BAB II LANDASAN TEORI ........................................................................... 6
2.1. ...................................................................................................... Pe
mbangkit Listrik Tenaga Gas .................................................................. 6
2.1.1. .............................................................................................. Pri
nsip Siklus PLTG ........................................................................ 7
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Universitas Sumatera Utara
2.1.2. .............................................................................................. Ke
rja PLTG...................................................................................... 8
2.1.3. .............................................................................................. O
perasi PLTG ................................................................................ 9
2.1.4. .............................................................................................. Ba
gian Utama PLTG ..................................................................... 10
2.1.4.1. Turbin.............................................................................. 10
2.1.4.2. Kompresor ...................................................................... 12
2.1.4.3. Ruang Bakar (Combustion Chamber)............................. 12
2.1.4.4. Generator ........................................................................ 13
2.1.5. .............................................................................................. K
omponen Bantu PLTG .............................................................. 14
2.1.5.1Udara Dalam (Air Inlet) .................................................... 14
2.1.5.2. Sistem-Sistem Pada Turbin Gas ..................................... 14
2.2. ......................................................................................................
PLTG GT 2.1 ........................................................................................ 15
2.3. ...................................................................................................... Al
at Ukur Yang Dipakai ........................................................................... 16
2.4. ...................................................................................................... K
onsep Maintenanc ................................................................................. 17
2.4.1. Tujuan Maintenance ................................................................... 19
2.4.2.Jenis – Jenis Maintenance ............................................................ 20
2.5. ...................................................................................................... Fa
ilure Modes And Effects Analysis (FMEA) ........................................... 23
2.6. ...................................................................................................... To
tal Produksi Maintenance...................................................................... 28
2.6.1.Pengertian..................................................................................... 28
2.6.2.Tujuan Total Productive Maintenance (TPM) ............................. 33
2.6.3.Manfaat Total Productive Maintenance (TPM) ........................... 33
2.7. ...................................................................................................... Ov
erall Equipment Effectiveness (OEE).................................................... 34
2.7.1.Availability Ratio ......................................................................... 35
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Universitas Sumatera Utara
2.7.2.Performance Ratio ....................................................................... 36
2.7.3.Quality Ratio ................................................................................ 36
2.8. ...................................................................................................... Si
x Big Losess ........................................................................................... 37
BAB III METODOLOGI PENELITIAN ..................................................... 41
3.1. ......................................................................................................
Tempat dan Waktu Penelitian ............................................................... 41
3.1.1. .............................................................................................. Te
mpat Penelitian .......................................................................... 41
3.1.2. .............................................................................................. W
aktu Penelitian ........................................................................... 41
3.2. ......................................................................................................
Parameter Penelitian.............................................................................. 41
3.3. ...................................................................................................... Su
mber dan Jenis Data .............................................................................. 42
3.4. ...................................................................................................... Va
riabel Penelitian..................................................................................... 42
3.5. ...................................................................................................... Pe
laksanaan Penelitian .............................................................................. 43
3.6. ......................................................................................................
Sistematis Pengolahan Data .................................................................. 44
3.7. ......................................................................................................
Analisa Data dan Pemecahan Masalah ................................................. 45
3.8. ...................................................................................................... Pe
ngumpulan Data .................................................................................... 46
3.8.1.Data Waktu Planned Downtime / Pemeliharaan GT 2.1 ............. 50
3.8.2.Data Waktu Downtime GT 2.1 ..................................................... 50
3.8.3.Data Waktu Setup Mesin GT 2.1 ................................................. 51
3.8.4.Data Produksi Mesin GT 2.1 ........................................................ 52
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BAB IV PENGOLAHAN DATA DAN ANALISA ...................................... 53
4.1. ...................................................................................................... Da
ta Analisa Efek Ragam Kegagalan Aktual ............................................ 53
4.2. ...................................................................................................... Sa
fety, Health dan Environment ................................................................ 53
4.3. ......................................................................................................
Pengolahan Data.................................................................................... 53
4.3.1.Perhitungan Availability (AV) ...................................................... 55
4.3.2.Perhitungan Performance Efficiency............................................ 56
4.3.3.Perhitungan Rate Of Quality Product (RQP) ............................... 57
4.3.4.Perhitungan Overall Equipment Effectiveness (OEE).................. 58
4.4. ...................................................................................................... Pe
rhitungan Six Big Losess ....................................................................... 59
4.4.1. .............................................................................................. D
owntime Losess............................................................................ 59
4.4.1.1. Equipment Failure/ Breakdowns .................................. 60
4.4.1.2. Setup and Ajustment Loss ............................................. 61
4.4.2. .............................................................................................. Sp
eed Losess .................................................................................... 62
4.4.2.1. Idling and Minor Stoppages Loss ................................. 62
4.4.2.2. Reduce Speed ................................................................ 63
4.4.3. .............................................................................................. De
fect Losess.................................................................................... 63
4.4.3.1. Yield/ Scrap Loss .......................................................... 64
4.4.3.2. Rework Loss.................................................................. 64
4.5. ......................................................................................................
Analisa Perhitungan .............................................................................. 65
4.5.1.Analisa Perhitungan Overall Equipment Effectiveness (OEE) .... 65
4.5.2.Perhitungan Six Big Losess .......................................................... 66
4.5.3.Penyelesaian Masalah .................................................................. 67
4.5.3.1. Penyelesaian Masalah Six Big Losess ........................... 67
4.5.3.2. Penerapan Total Productive Maintenance .................... 68
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Universitas Sumatera Utara
BAB V KESIMPULAN DAN SARAN .......................................................... 69
5.1. ......................................................................................................
Kesimpulan ........................................................................................... 69
5.2. ...................................................................................................... Sa
ran.......................................................................................................... 70
DAFTAR PUSTAKA ...................................................................................... 71
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DAFTAR GAMBAR
Gambar 2.1. Komponen Sederhana PLTG ......................................................... 6
Gambar 2.2. Siklus Brayton ................................................................................ 8
Gambar 2.3. Turbin Gas .................................................................................... 11
Gambar 2.4. Kompresor .................................................................................... 12
Gambar 2.5. Combustion Chamber................................................................... 13
Gambar 2.6. Generator ...................................................................................... 14
Gambar 2.7. Pillar – pilar TPM......................................................................... 30
Gambar 2.8. Garis Besar Perhitungan OEE Berdasarkan Six Big Losess ......... 40
Gambar 3.1. Tahapan Proses Pemecahan Masalah ........................................... 46
Gambar 4.1. Grafik Persentase OEE ................................................................. 66
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DAFTAR TABEL
Tabel 2.1. Data Spesifikasi Gas Turbin ............................................................ 10
Tabel 2.2. Data Spesifikasi Generator............................................................... 13
Tabel 2.3. Data Umum Unit GT 21................................................................... 16
Tabel 2.4. Keparahan ........................................................................................ 25
Tabel 2.5. Kekerapan ........................................................................................ 25
Tabel 2.6. Deteksi ............................................................................................. 26
Tabel 3.1. Log Sheet Rancangan Parameter Penelitian ..................................... 41
Tabel 3.2. Parameter Penelitian ........................................................................ 42
Tabel 3.3. Desain Analisa Efek Ragam Kegagalan ........................................ 48
Tabel 3.4. Data Pemeliharaan GT 2.1 Periode Januari – Desember 2015 ........ 50
Tabel 3.5. Data Waktu Terjadi Kerusakan (Breakdown) GT 2......................... 51
Tabel 3.6. Data Waktu Setup GT 2.1 ................................................................ 51
Tabel 3.7. Data Produksi GT 2.1....................................................................... 52
Tabel 4.1. Analisa Efek Ragam Kegagalan Secara Aktual .............................. 54
Tabel 4.2. World Class of OEE ......................................................................... 55
Tabel 4.3. Availability GT 2.1 ........................................................................... 56
Tabel 4.4. Performance Efficiency GT 2.1 ....................................................... 57
Tabel 4.5. Rate Of Quality Production Turbin Gas .......................................... 58
Tabel 4.6. OEE Turbin Gas GT 2.1 .................................................................. 59
Tabel 4.7. Breakdown Losess Turbin Gas GT 2.1 ............................................ 60
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Universitas Sumatera Utara
Tabel 4.8. Setup and Adjustment Losess Turbin Gas 2.1 .................................. 61
Tabel 4.9. Idling and Minor Stoppages LossesTurbin Gas GT 2.1 .................. 62
Tabel 4.10. Reduced Speed Turbin Gas GT 2.1 ................................................ 63
Tabel 4.11. Yield / Scrap Loss Turbin Gas GT 2.1 ........................................... 64
Tabel 4.12. Rework Loss Turbin Gas GT 2.1.................................................... 65
Tabel 4.13. Persentase OEE Setiap Periode ...................................................... 66
Tabel 4.14. Persentase Faktor Six Big Losess Turbin Gas GT 2.1 .................... 67
Tabel 4.15. Penyelesaian Masalah .................................................................... 67
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Universitas Sumatera Utara
DENGAN METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE)
UNTUK MEMETAKAN EFISIENSI PRODUKSI
DI PT. PLN SECANANG – BELAWAN
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi
Syarat Memperoleh Gelar Sarjana Teknik
MAWARDY NP HUTASOIT
110401059
DEPARTEMEN TEKNIK MESIN
FAKULTAS TEKNIK
UNIVERSITAS SUMATERA UTARA
MEDAN
2016
Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis panjatkan kepada Tuhan Yang Maha Esa, atas
berkat dan karunia-Nya maka skripsi ini dapat diselesaikan dengan baik.
Skripsi yang berjudul " Analisa pada Pembangkit Listrik Tenaga Gas GT 2.1
dengan Metode Overall Equipment Effectiveness (OEE) untuk Memetakan
Efisiensi Produksi Di PT. PLN SECANANG – BELAWAN " ini penulis susun
untuk memenuhi persyaratan kurikulum Sarjana Strata-1 (S-1) pada Departemen
Teknik Mesin, Fakultas Teknik, Universitas Sumatera Utara.
Penulis mengucapkan rasa terima kasih yang sebesar-besarnya atas semua
bantuan yang telah diberikan, baik secara langsung maupun tidak langsung selama
penyusunan tugas akhir ini hingga selesai. Secara khusus rasa terimakasih tersebut
penulis sampaikan kepada:
1. Kedua orang tua Ayahanda Drs. S. Hutasoit, Ibunda M. Lumbantoruan B.A
dan keluarga besar Hutasoit atas doa, kasih sayang, pengorbanan, tanggung
jawab yang selalu menyertai penulis, dan memberikan penulis semangat yang
luar biasa sehingga penulis dapat menyelesaikan skripsi ini.
2. Bapak Dr. Ir. M.Sabri, MT selaku dosen pembimbing yang telah memberikan
bimbingan dan dorongan dalam penyusunan tugas akhir ini.
3. Bapak Dr. Ing. Ir Ikhwansyah Isranuri selaku Ketua Jurusan Departemen
Teknik Mesin, Fakultas Teknik, Universitas Sumatera Utara.
4. Ir. Syahril Gultom, MT selaku Sekretaris Departemen Teknik Mesin, Fakultas
Teknik, Universitas Sumatera Utara.
5. Bapak Ir. Tugiman, MT selaku Koordinator Skripsi Departemen Teknik Mesin,
Fakultas Teknik, Universitas Sumatera Utara.
6. Seluruh Dosen dan seluruh Pegawai Administrasi Departemen Teknik Mesin,
juga kepada Staf Fakultas Teknik, Universitas Sumatera Utara, atas ilmu,
bimbingan dan bantuannya hingga penulis selesai menyusun tugas akhir ini.
7. Rekan-rekan Stambuk 2011, Penggo, link kupi, PK2L, Olu, Tim Horas
Universitas Sumatera Utara yang juga telah banyak membantu penulis dan
memberi semangat.
i
Universitas Sumatera Utara
Penulis menyadari bahwa tugas akhir ini jauh dari kata sempurna, baik
dari segi materi maupun penyajiannya. Untuk itu saran dan kritik yang
membangun sangat diharapkan dalam penyempurnaan tugas akhir ini. Terakhir
penulis berharap, semoga tugas akhir ini dapat memberikan hal yang bermanfaat
dan menambah wawasan bagi pembaca dan khususnya bagi penulis juga.
Medan,
November 2016
Penulis,
Mawardy NP Hutasoit
NIM : 110401059
ii
Universitas Sumatera Utara
ABSTRAK
PT. Perusahaan Listrik Negara (PLN) Secanang – Belawan, merupakan
perusahaan yang bergerak di bidang pelayanan terhadap pelanggan dan listrik.
Energi listrik merupakan sumber daya yang sangat dibutuhkan dalam rangka
meningkatkan kesejahteraan masyarakat, yang dalam prosesnya tidak terlepas dari
problem efektivitas paralatan atau mesin. Penerapan metode Failure Mode And
Effect Analisys (FMEA) merupakan suatu prosedur untuk mengidentifikasi
kegagalan
produk
yang
terjadi
sedangkan
metode
Overall
Equipment
Effectivenees (OEE) merupakan suatu pengukuran efektivitas pemakaian suatu
mesin/peralatan dengan menghitung ketersediaan mesin, performansi dan kualitas
produk yang dihasilkan. Perhitungan six big losses dilakukan untuk mengetahui
kerugian yang menyebabkan rendahnya nilai OEE. Total Productive Maintenance
merupakan suatu prinsip manajemen untuk meningkatkan produktivitas dan
efisiensi produksi perusahaan dengan menggunakan mesin secara efektif.
Penelitian ini mengarah pada pengukuran nilai OEE dalam satu lini produksi.
Berdasarkan perhitungan nilai OEE pada Turbin Gas GT 2.1 selama bulan Januari
2015 – Desember 2015 diperoleh nilai Availability = 99,86% kondisi ini dianggap
sempurna sebesar 100%, Performance efesiensi = 84,53% kondisi ini dianggap
kelas dunia sebesar 85%, Quality of rate = 99,67% kondisi ini dianggap sempurna
sebesar 100%, Dan nilai hasil OEE = 84,15% kondisi ini dianggap kelas dunia
skor yang cocok untuk dijadikan goal jangka panjang.
Kata kunci ; FMEA, OEE, Availability, Performance efesiensi, Quality of rate
iii
Universitas Sumatera Utara
ABSTRACT
PT. State Electricity Company (PLN) Secanang - Belawan, is a company
engaged in the field of customer service and electricity. Electrical energy is a
resource that is needed in order to improve the welfare of society, which is in the
process can not be separated from the problem of effectiveness paralatan or
machine. Application of the method Failure Mode And Effect Analisys (FMEA) is
a procedure to identify product failures that occurred while the method
Effectivenees Overall Equipment (OEE) is a measurement of the effectiveness of
the use of a machine / equipment by calculating machine availability, performance
and quality of the product. Six big losses calculation is performed to determine
damages to the low value of OEE. Total Productive Maintenance is a principle of
management to increase productivity and production efficiency for companies
using the machine effectively. This research led to the measurement of values
OEE in a single production line. Based on the calculation of OEE in Gas Turbine
GT 2.1 during the month of January 2015 - December 2015 obtained value
Availability = 99.86% This condition is considered perfect by 100%, Performance
efficiency = 84.53% This condition is considered world class by 85%, Quality of
rate = 99.67% is considered perfect condition at 100%, and the value of the OEE
= 84.15% is considered a world-class condition score is suitable to serve as goal. a
long-term.
Keywords ; FMEA,OEE, Availability, Performance efficiency, Quality of rate
iv
Universitas Sumatera Utara
DAFTAR ISI
KATA PENGANTAR ........................................................................................ i
ABSTRAK ........................................................................................................iii
DAFTAR ISI ...................................................................................................... v
DAFTAR GAMBAR ......................................................................................viii
DAFTAR TABEL ............................................................................................ ix
BAB I PENDAHULUAN .................................................................................. 1
1.1. ...................................................................................................... La
tar Belakang ............................................................................................ 1
1.2. ...................................................................................................... Po
kok Permasalahan.................................................................................... 2
1.3. ...................................................................................................... Ru
musan Masalah ........................................................................................ 3
1.4. ...................................................................................................... Ba
tasan Masalah Penelitian ......................................................................... 3
1.5. ...................................................................................................... As
umsi – Asumsi ......................................................................................... 3
1.6. ...................................................................................................... Tu
juan Penelitian ......................................................................................... 3
1.7. ...................................................................................................... M
anfaat Penulisan ...................................................................................... 4
1.8. ...................................................................................................... Si
stematika Penulisan Skripsi .................................................................... 4
BAB II LANDASAN TEORI ........................................................................... 6
2.1. ...................................................................................................... Pe
mbangkit Listrik Tenaga Gas .................................................................. 6
2.1.1. .............................................................................................. Pri
nsip Siklus PLTG ........................................................................ 7
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Universitas Sumatera Utara
2.1.2. .............................................................................................. Ke
rja PLTG...................................................................................... 8
2.1.3. .............................................................................................. O
perasi PLTG ................................................................................ 9
2.1.4. .............................................................................................. Ba
gian Utama PLTG ..................................................................... 10
2.1.4.1. Turbin.............................................................................. 10
2.1.4.2. Kompresor ...................................................................... 12
2.1.4.3. Ruang Bakar (Combustion Chamber)............................. 12
2.1.4.4. Generator ........................................................................ 13
2.1.5. .............................................................................................. K
omponen Bantu PLTG .............................................................. 14
2.1.5.1Udara Dalam (Air Inlet) .................................................... 14
2.1.5.2. Sistem-Sistem Pada Turbin Gas ..................................... 14
2.2. ......................................................................................................
PLTG GT 2.1 ........................................................................................ 15
2.3. ...................................................................................................... Al
at Ukur Yang Dipakai ........................................................................... 16
2.4. ...................................................................................................... K
onsep Maintenanc ................................................................................. 17
2.4.1. Tujuan Maintenance ................................................................... 19
2.4.2.Jenis – Jenis Maintenance ............................................................ 20
2.5. ...................................................................................................... Fa
ilure Modes And Effects Analysis (FMEA) ........................................... 23
2.6. ...................................................................................................... To
tal Produksi Maintenance...................................................................... 28
2.6.1.Pengertian..................................................................................... 28
2.6.2.Tujuan Total Productive Maintenance (TPM) ............................. 33
2.6.3.Manfaat Total Productive Maintenance (TPM) ........................... 33
2.7. ...................................................................................................... Ov
erall Equipment Effectiveness (OEE).................................................... 34
2.7.1.Availability Ratio ......................................................................... 35
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2.7.2.Performance Ratio ....................................................................... 36
2.7.3.Quality Ratio ................................................................................ 36
2.8. ...................................................................................................... Si
x Big Losess ........................................................................................... 37
BAB III METODOLOGI PENELITIAN ..................................................... 41
3.1. ......................................................................................................
Tempat dan Waktu Penelitian ............................................................... 41
3.1.1. .............................................................................................. Te
mpat Penelitian .......................................................................... 41
3.1.2. .............................................................................................. W
aktu Penelitian ........................................................................... 41
3.2. ......................................................................................................
Parameter Penelitian.............................................................................. 41
3.3. ...................................................................................................... Su
mber dan Jenis Data .............................................................................. 42
3.4. ...................................................................................................... Va
riabel Penelitian..................................................................................... 42
3.5. ...................................................................................................... Pe
laksanaan Penelitian .............................................................................. 43
3.6. ......................................................................................................
Sistematis Pengolahan Data .................................................................. 44
3.7. ......................................................................................................
Analisa Data dan Pemecahan Masalah ................................................. 45
3.8. ...................................................................................................... Pe
ngumpulan Data .................................................................................... 46
3.8.1.Data Waktu Planned Downtime / Pemeliharaan GT 2.1 ............. 50
3.8.2.Data Waktu Downtime GT 2.1 ..................................................... 50
3.8.3.Data Waktu Setup Mesin GT 2.1 ................................................. 51
3.8.4.Data Produksi Mesin GT 2.1 ........................................................ 52
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BAB IV PENGOLAHAN DATA DAN ANALISA ...................................... 53
4.1. ...................................................................................................... Da
ta Analisa Efek Ragam Kegagalan Aktual ............................................ 53
4.2. ...................................................................................................... Sa
fety, Health dan Environment ................................................................ 53
4.3. ......................................................................................................
Pengolahan Data.................................................................................... 53
4.3.1.Perhitungan Availability (AV) ...................................................... 55
4.3.2.Perhitungan Performance Efficiency............................................ 56
4.3.3.Perhitungan Rate Of Quality Product (RQP) ............................... 57
4.3.4.Perhitungan Overall Equipment Effectiveness (OEE).................. 58
4.4. ...................................................................................................... Pe
rhitungan Six Big Losess ....................................................................... 59
4.4.1. .............................................................................................. D
owntime Losess............................................................................ 59
4.4.1.1. Equipment Failure/ Breakdowns .................................. 60
4.4.1.2. Setup and Ajustment Loss ............................................. 61
4.4.2. .............................................................................................. Sp
eed Losess .................................................................................... 62
4.4.2.1. Idling and Minor Stoppages Loss ................................. 62
4.4.2.2. Reduce Speed ................................................................ 63
4.4.3. .............................................................................................. De
fect Losess.................................................................................... 63
4.4.3.1. Yield/ Scrap Loss .......................................................... 64
4.4.3.2. Rework Loss.................................................................. 64
4.5. ......................................................................................................
Analisa Perhitungan .............................................................................. 65
4.5.1.Analisa Perhitungan Overall Equipment Effectiveness (OEE) .... 65
4.5.2.Perhitungan Six Big Losess .......................................................... 66
4.5.3.Penyelesaian Masalah .................................................................. 67
4.5.3.1. Penyelesaian Masalah Six Big Losess ........................... 67
4.5.3.2. Penerapan Total Productive Maintenance .................... 68
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BAB V KESIMPULAN DAN SARAN .......................................................... 69
5.1. ......................................................................................................
Kesimpulan ........................................................................................... 69
5.2. ...................................................................................................... Sa
ran.......................................................................................................... 70
DAFTAR PUSTAKA ...................................................................................... 71
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DAFTAR GAMBAR
Gambar 2.1. Komponen Sederhana PLTG ......................................................... 6
Gambar 2.2. Siklus Brayton ................................................................................ 8
Gambar 2.3. Turbin Gas .................................................................................... 11
Gambar 2.4. Kompresor .................................................................................... 12
Gambar 2.5. Combustion Chamber................................................................... 13
Gambar 2.6. Generator ...................................................................................... 14
Gambar 2.7. Pillar – pilar TPM......................................................................... 30
Gambar 2.8. Garis Besar Perhitungan OEE Berdasarkan Six Big Losess ......... 40
Gambar 3.1. Tahapan Proses Pemecahan Masalah ........................................... 46
Gambar 4.1. Grafik Persentase OEE ................................................................. 66
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DAFTAR TABEL
Tabel 2.1. Data Spesifikasi Gas Turbin ............................................................ 10
Tabel 2.2. Data Spesifikasi Generator............................................................... 13
Tabel 2.3. Data Umum Unit GT 21................................................................... 16
Tabel 2.4. Keparahan ........................................................................................ 25
Tabel 2.5. Kekerapan ........................................................................................ 25
Tabel 2.6. Deteksi ............................................................................................. 26
Tabel 3.1. Log Sheet Rancangan Parameter Penelitian ..................................... 41
Tabel 3.2. Parameter Penelitian ........................................................................ 42
Tabel 3.3. Desain Analisa Efek Ragam Kegagalan ........................................ 48
Tabel 3.4. Data Pemeliharaan GT 2.1 Periode Januari – Desember 2015 ........ 50
Tabel 3.5. Data Waktu Terjadi Kerusakan (Breakdown) GT 2......................... 51
Tabel 3.6. Data Waktu Setup GT 2.1 ................................................................ 51
Tabel 3.7. Data Produksi GT 2.1....................................................................... 52
Tabel 4.1. Analisa Efek Ragam Kegagalan Secara Aktual .............................. 54
Tabel 4.2. World Class of OEE ......................................................................... 55
Tabel 4.3. Availability GT 2.1 ........................................................................... 56
Tabel 4.4. Performance Efficiency GT 2.1 ....................................................... 57
Tabel 4.5. Rate Of Quality Production Turbin Gas .......................................... 58
Tabel 4.6. OEE Turbin Gas GT 2.1 .................................................................. 59
Tabel 4.7. Breakdown Losess Turbin Gas GT 2.1 ............................................ 60
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Tabel 4.8. Setup and Adjustment Losess Turbin Gas 2.1 .................................. 61
Tabel 4.9. Idling and Minor Stoppages LossesTurbin Gas GT 2.1 .................. 62
Tabel 4.10. Reduced Speed Turbin Gas GT 2.1 ................................................ 63
Tabel 4.11. Yield / Scrap Loss Turbin Gas GT 2.1 ........................................... 64
Tabel 4.12. Rework Loss Turbin Gas GT 2.1.................................................... 65
Tabel 4.13. Persentase OEE Setiap Periode ...................................................... 66
Tabel 4.14. Persentase Faktor Six Big Losess Turbin Gas GT 2.1 .................... 67
Tabel 4.15. Penyelesaian Masalah .................................................................... 67
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