Analisa Total Productive Maintenance Pada Mesin Injection Molding Dengan Menggunakan Metode Overall Equipment Effectiveness (OEE) di PT. Tirta Sibayakindo (TSI)
ANALISA TOTAL PRODUCTIVE MAINTENANCE PADA MESIN
INJECTION MOLDING DENGAN MENGGUNAKAN
METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE)
DI PT. TIRTA SIBAYAKINDO (TSI)
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi
Syarat Memperoleh Gelar Sarjana Teknik
Oleh :
ROYS ARJUN TARIGAN
NIM : 110401058
DEPARTEMEN TEKNIK MESIN
FAKULTAS TEKNIK
UNIVERSITAS SUMATERA UTARA
MEDAN
2016
Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis panjatkan kehadirat Tuhan Yang Maha Esa dimana
atas berkat dan rahmat- Nya yang berlimpah penulis dapat menyelesaikan skripsi ini
dengan baik tepat pada waktunya, dimana skripsi ini disusun untuk memenuhi syarat
kelulusan Strata 1 (S1) di Departemen Teknik Mesin Fakultas Teknik Universitas
Sumatera Utara.
Dalam penyusunan skripsi ini penulis banyak menghadapi rintangan,
hambatan dan tantangan, tetapi oleh karena berkat dan penyertaan-Nya, bimbingan
dari Dosen Pembimbing, dan disiplin ilmu yang diperoleh maka skripsi ini dapat
diselesaikan dengan penyajian sedemikian rupa.
Dalam penyusunan dan penulisan skripsi ini tidak terlepas dari bantuan,
bimbingan serta dukungan dari berbagai pihak. Oleh karena itu dalam kesempatan ini
penulis dengan tulus dan kerendahan hati ingin mengucapkan terima kasih kepada :
1. Bapak Ir. Alfian Hamsi, M.Sc selaku dosen pembimbing yang telah
mengarahkan dan membimbing penulis.
2. Bapak Dr.Ing.Ir.Ikwansyah Isranuri, selaku Ketua Departemen Teknik Mesin
Fakultas Teknik USU.
3. Seluruh staf pengajar dan staf tata usaha Departemen Teknik Mesin yang telah
berjasa membimbing serta membantu segala keperluan penulis selama penulis
kuliah.
4. Bapak A. Kaban selaku Team Leader PT. Tirta Sibayakindo Berastagi
sekaligus pembimbing lapangan yang telah memberikan bimbingan, nasehat
dan doa selama penulis melakukan penelitian.
5. Seluruh staf pegawai dan teknisi PT. Tirta Sibayakindo Berastagi yang telah
memberikan dukungan, doa serta partisipasinya selama penulis menyelesaikan
skripsi sehingga penulisan skripsi ini berjalan dengan lancar.
6. Kedua orang tua penulis, Bapak Alm. J.Tarigan dan Ibu S. br Perangin-angin
yang memberikan dukungan penuh dalam kasih sayang, doa-doa dan materil.
Universitas Sumatera Utara
7. Saudara kandung penulis, kakanda Melpina S. br Tarigan dan keluarga,
beserta seluruh keluarga yang tidak bisa disebutkan satu persatu.
8. Rekan seperjuangan dalam penelitian saudara Basri Sembiring yang telah
berbagi waktu dan pemikiran selama proses pengerajaan skripsi.
9. Teman – teman mahasiswa stambuk 2011 Departemen Teknik Mesin Fakultas
Teknik Universitas Sumatera Utara
10. Keluarga besar IMKA (Ikatan Mahasiswa Karo) PANDE KALIAGA FTUSU yang telah memberikan semangat kepada penulis selama berkuliah di
Departemen Teknik Mesin Fakultas Teknik Universitas Sumatera Utara.
11. Keluarga besar Pemuda/I Juhar Medan-Sekitarnya (PPJ-MS) yang telah
memberikan dukungan kepada penulis selama kuliah di Departemen Teknik
Mesin Fakultas Teknik Universitas Sumatera Utara.
12. Semua pihak yang telah banyak membantu penulis dalam menyelesaikan
skripsi ini.
Dengan demikian, penulisan skripsi ini ditulis dengan apa adanya, oleh karena
itu penulis mengharapkan kritik dan saran yang bersifat membangun agar kedepannya
dapat lebih baik lagi.
Dengan doa dan harapan dari penulis, semoga tulisan ini memberikan manfaat
kepada pembaca. Akhir kata penulis ucapkan banyak terima kasih dan Tuhan
memberkati.
Medan, Mei 2016
Penulis,
Roys A. Tarigan
NIM : 110401058
Universitas Sumatera Utara
ABSTRAK
Losses dapat mengurangi efektifitas penggunaan peralatan dalam kegiatan proses
produksi. Untuk mengetahui dan meminimumkan losses yang terjadi, diperlukan
adanya evaluasi kinerja dari peralatan produksi. Mesin Injection Molding adalah
salah satu jenis mesin yang digunakan dalam proses produksi di PT. Tirta
Sibayakindo yang akan dievaluasi efektifitasnya. Pengukuran efektifitas mesin
injection molding dapat dilakukan dengan menggunakan metode Overall Equipment
Effectiveness untuk mencegah terjadi 6 kerugian besar (Six Big Losses) yaitu,
breakdown losses, setup and adjusment losses, idling and minor stoppages losse,
reduced speed losses, rework losses dan yield scrap losses. Dalam perhitungan, OEE
mengukur efektifitas dengan menggunakan tiga sudut pandang untuk
mengidentifikasi six big losses, yaitu availability, performance dan quality.Dari hasil
pengolahan data, didapat nilai rata – rata OEE pada periode Maret 2015 – Maret 2016
adalah 75.94 %. Nilai Breakdown losses sebesar 1.47 %, hasil setup and adjusment
losses sebesar 1.37 % , hasil Idling and minor stoppages Losses sebesar 8.24 %, hasil
Reduced speed Losses sebesar 20.43 % , hasil Rework losses dan Yield / scrap losses
sebesar 0 %.
Kata Kunci: Availability, Quality,Performance, OEE, Six Big Losses
Universitas Sumatera Utara
ABSTRACT
Losses can reduce the effectiveness of the use of equipment in the production process.
To know and to minimize losses that occur, there needs to evaluate the performance
of the production equipment. Injection Molding Machine is one type of machines used
in the production process in PT. Tirta Sibayakindo be evaluated effectiveness.
Measurement of the effectiveness of the injection molding machine can be
accomplished by using the Overall Equipment Effectiveness to prevent it from
occurring 6 big losses (Six Big Losses), ie, breakdown losses, setup and adjustment
losses, idling and minor stoppages losse, reduced speed losses, rework losses and
yield scrap losses , In the calculation, OEE measures the effectiveness of using three
viewpoints to identify the six big losses, namely availability, performance and quality.
From the data processing, obtained value - average OEE in the period March 2015 March 2016 is 75.94%. Value Breakdown losses amounted 1.47%, the result of setup
and adjustment losses at 1.37%, results Idling and minor stoppages% Losses at 8.24,
the results Reduced speed Losses at 20.43%, results Rework losses and Yield / scrap
losses amounted to 0%.
Keywords: Availability, Quality, Performance, OEE, Six Big Losses
Universitas Sumatera Utara
DAFTAR ISI
KATA PENGANTAR ....................................................................................... i
ABSTRAK ........................................................................................................ iii
DAFTAR ISI ...................................................................................................... v
DAFTAR GAMBAR ....................................................................................... viii
DAFTAR TABEL ............................................................................................. ix
DAFTAR RUMUS ............................................................................................ x
BAB I PENDAHULUAN
1.1 Latar Belakang ............................................................................................. 1
1.2 Tujuan Penelitian ......................................................................................... 2
1.3 Pembatasan Masalah .................................................................................... 3
1.4 Manfaat Penelitian ....................................................................................... 3
1.5 Sistematika Penulisan .................................................................................. 4
BAB II MESIN INJECTION MOLDING
2.1 Mesin Injection Molding .............................................................................. 5
2.1.1 Langkah-Langkah Injection Molding .................................................... 6
2.1.2. Komponen-komponen Utama Sistem Injection Molding ..................... 7
2.1.2.1 Mold Clamp Unit ........................................................................... 8
2.1.2.2 Injection Unit ................................................................................. 12
2.1.3 Komponen Pendukung Mesin Injeksi ................................................... 14
2.1.4 Parameter-parameter Proses Injection Molding .................................. 15
2.1.5. Jenis-jenis Analisa Moldflow Plastic Insight ...................................... 16
2.1.6. Pengertian Plastik dalam Desain Plastik Molding .............................. 17
2.1.7. Prinsip Umum Desain Mold ............................................................... 18
2.1.8. Cacat Produksi Pada Proses Injeksi Plastik ........................................ 18
Universitas Sumatera Utara
BAB III TEORI PERAWATAN (MAINTENANCE)
3.1 Maintenance (Perawatan) ............................................................................ 22
3.1.1 Pengertian Maintenance ........................................................................ 22
3.1.2 Tujuan Maintenance .............................................................................. 23
3.1.3 Fungsi Pemeliharaan ............................................................................. 25
3.1.4 Jenis-Jenis Maintenance ........................................................................ 25
3.1.5 Konsep-Konsep Pemeliharaan .............................................................. 32
3.2 Total Productive Maintenance (TPM) ........................................................ 34
3.2.1 Sejarah TPM ......................................................................................... 34
3.2.2 Pengertian Total Productive Maintenance ............................................ 35
3.2.3 Tujuan Total Productive Maintenance .................................................. 38
3.2.4 Manfat Total Productive Maintenance .................................................. 39
3.2.5 Tahapan Penerapan TPM ...................................................................... 39
3.3 Analisa Produktivitas :Six Big Losses (6 Kerugian Besar) ......................... 40
3.4 Overall Equipment Effectiveness (OEE) .................................................... 42
3.4.1 Pengertian OEE ..................................................................................... 42
3.4.2 Tujuan OEE........................................................................................... 43
3.4.3 Perhitungan OEE................................................................................... 44
3.5 Diagram Sebab Akibat ............................................................................... 47
BAB IV METODE PENELITIAN
4.1 Tempat dan Waktu penelitian ..................................................................... 48
4.1.1
Tempat penelitian ............................................................................... 48
4.1.2
Waktu Penelitian ................................................................................ 48
4.2 Rancangan Penelitian .................................................................................. 48
4.3 Objek Penelitian ......................................................................................... 48
4.4 Instrumen Penelitian ................................................................................... 48
4.5 Pelaksanaan Penelitian ............................................................................... 49
4.6 Pengolahan Data ......................................................................................... 50
4.7 Analisis dan Pemecahan Masalah ............................................................... 51
Universitas Sumatera Utara
BAB V PENGOLAHAN DATA
5.1 Pengumpulan Data ...................................................................................... 52
5.2 Pengolahan Data.......................................................................................... 55
5.2.1 Perhitungan Availabilty ........................................................................ 55
5.2.2 Perhitungan Performance Efficiency .................................................... 57
5.2.3 Perhitungan Rate of Quality .................................................................. 59
5.2.4 Perhitungan OEE................................................................................... 61
5.2.5 Perhitungan OEE : Six Big Losses........................................................ 63
5.2.5.1 Downtime Losses ............................................................................ 63
5.2.5.2 Speed Losse..................................................................................... 65
5.2.5.3 Defect Losses .................................................................................. 67
BAB VI DISKUSI DAN PEMECAHAN MASALAH
6.1 Analisa Perhitungan OEE ........................................................................... 69
6.2 Analisa Perhitungan OEE : Six Big Losses ................................................ 70
6.3 Analisa Diagram Sebab Akibat ................................................................... 71
6.4 Usulan Penyelesaian Masalah ..................................................................... 73
6.4.1 Usulan Penyelesaian Masalah Six Big Losses ...................................... 73
6.4.2 Penerapan Total Productive Maintenance ............................................. 74
BAB VII KESIMPULAN DAN SARAN
6.1 Kesimpulan ................................................................................................. 75
6.2 Saran............................................................................................................ 76
DAFTAR PUSTAKA ...................................................................................... 77
LAMPIRAN ..................................................................................................... 79
Universitas Sumatera Utara
DAFTAR GAMBAR
Gambar 2.1 Proses mold .................................................................................... 6
Gambar 2.2 Injection unit dan clamping unit..................................................... 7
Gambar 2.3 Mold tipe dua plate......................................................................... 9
Gambar 2.4 Mold tipe tiga plate ....................................................................... 10
Gambar 2.5 Bagian – bagian injection molding................................................ 14
Gambar 2.6 Panel control.................................................................................. 14
Gambar 3.1 Delapan (8) Pilar TPM .................................................................. 38
Gambar 3.2 Model OEE.................................................................................... 43
Gambar 4.1 Diagram Alir Penelitian ................................................................ 51
Gambar 5.1 Grafik nilai availability injection molding .................................... 57
Gambar 5.2 Grafik nilai performance injection molding .................................. 59
Gambar 5.3 Grafik nilai Quality injection molding .......................................... 61
Gambar 5.4 Grafik nilai OEE injection molding .............................................. 62
Gambar 6.1 Diagram persentase Six Big Losses .............................................. 71
Gambar 6.2 Diagram fishbone mesin injection molding..................................72
Universitas Sumatera Utara
DAFTAR TABEL
Tabel 3.1 Six big losses dan perhitungan OEE ...............................................
Tabel 3.2 Standar OEE ....................................................................................
Tabel 5.1 Data waktu breakdown dan Setup pada
mesinInjection Molding ..................................................................
Tabel 5.2 Data waktu pemeliharaan (planned downtime)
mesin Injection Molding .................................................................
Tabel 5.3 Data produksi mesin injection molding
periode Maret 2015 – Maret 2016 ...................................................
Tabel 5.4 Nilai Availabilitymesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.5 Nilai Performance Effeciency mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.6 Nilai Rate of Quality Productmesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.7 Nilai Overall Equipment Effectiveness (OEE)
mesin injection molding periode Mar 2015 – Mar 2016.................
Tabel 5.8 Nilai Breakdown losses mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.9 Nilai Setup and Adjusment losses mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.10 Nilai Idling and Minor Stoppages losses mesin
injection molding periode Mar 2015 – Mar 2016 ...........................
Tabel 5.11 NilaiReduced Speedlosses mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 6.1 Persentase pencapaian mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 6.2 Persentase faktor Six Big Losses mesin injection molding
periode Maret 2015 – Maret 2016 ...................................................
Tabel 6.3 Usulan Penyelesaian Masalah .........................................................
44
47
53
54
55
56
58
60
62
63
64
66
67
69
70
73
Universitas Sumatera Utara
DAFTAR RUMUS
Rumus 3.1
Rumus 3.2
Rumus 3.3
Rumus 3.4
Rumus 3.5
Rumus 3.6
Rumus 3.7
Rumus 3.8
Rumus 3.9
Rumus 3.10
Rumus 3.11
Rumus 3.12
Rumus 3.13
Rumus 3.14
Rumus 3.15
Rumus 3.16
Rumus 3.17
Breakdown Losses .............................................................................
Setup and Adjustment Losses ............................................................
Idling and Minor Stoppages Losses ...................................................
Reduced Speed Losses .......................................................................
Rework Losses ...................................................................................
Yield / Scrap Losses ...........................................................................
Nilai OEE ...........................................................................................
Nilai Availability................................................................................
Operation Time ..................................................................................
Loading Time .....................................................................................
Downtime ...........................................................................................
Performance Efficiency......................................................................
Operation Speed Rate.........................................................................
Net Operation Rate.............................................................................
Turunan Rumus Performance Efficiency ...........................................
Hasil Turunan Rumus Performance Efficiency .................................
Rate of Quality Product ......................................................................
40
41
41
41
41
42
44
44
45
45
45
45
46
46
46
46
46
Universitas Sumatera Utara
INJECTION MOLDING DENGAN MENGGUNAKAN
METODE OVERALL EQUIPMENT EFFECTIVENESS (OEE)
DI PT. TIRTA SIBAYAKINDO (TSI)
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi
Syarat Memperoleh Gelar Sarjana Teknik
Oleh :
ROYS ARJUN TARIGAN
NIM : 110401058
DEPARTEMEN TEKNIK MESIN
FAKULTAS TEKNIK
UNIVERSITAS SUMATERA UTARA
MEDAN
2016
Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis panjatkan kehadirat Tuhan Yang Maha Esa dimana
atas berkat dan rahmat- Nya yang berlimpah penulis dapat menyelesaikan skripsi ini
dengan baik tepat pada waktunya, dimana skripsi ini disusun untuk memenuhi syarat
kelulusan Strata 1 (S1) di Departemen Teknik Mesin Fakultas Teknik Universitas
Sumatera Utara.
Dalam penyusunan skripsi ini penulis banyak menghadapi rintangan,
hambatan dan tantangan, tetapi oleh karena berkat dan penyertaan-Nya, bimbingan
dari Dosen Pembimbing, dan disiplin ilmu yang diperoleh maka skripsi ini dapat
diselesaikan dengan penyajian sedemikian rupa.
Dalam penyusunan dan penulisan skripsi ini tidak terlepas dari bantuan,
bimbingan serta dukungan dari berbagai pihak. Oleh karena itu dalam kesempatan ini
penulis dengan tulus dan kerendahan hati ingin mengucapkan terima kasih kepada :
1. Bapak Ir. Alfian Hamsi, M.Sc selaku dosen pembimbing yang telah
mengarahkan dan membimbing penulis.
2. Bapak Dr.Ing.Ir.Ikwansyah Isranuri, selaku Ketua Departemen Teknik Mesin
Fakultas Teknik USU.
3. Seluruh staf pengajar dan staf tata usaha Departemen Teknik Mesin yang telah
berjasa membimbing serta membantu segala keperluan penulis selama penulis
kuliah.
4. Bapak A. Kaban selaku Team Leader PT. Tirta Sibayakindo Berastagi
sekaligus pembimbing lapangan yang telah memberikan bimbingan, nasehat
dan doa selama penulis melakukan penelitian.
5. Seluruh staf pegawai dan teknisi PT. Tirta Sibayakindo Berastagi yang telah
memberikan dukungan, doa serta partisipasinya selama penulis menyelesaikan
skripsi sehingga penulisan skripsi ini berjalan dengan lancar.
6. Kedua orang tua penulis, Bapak Alm. J.Tarigan dan Ibu S. br Perangin-angin
yang memberikan dukungan penuh dalam kasih sayang, doa-doa dan materil.
Universitas Sumatera Utara
7. Saudara kandung penulis, kakanda Melpina S. br Tarigan dan keluarga,
beserta seluruh keluarga yang tidak bisa disebutkan satu persatu.
8. Rekan seperjuangan dalam penelitian saudara Basri Sembiring yang telah
berbagi waktu dan pemikiran selama proses pengerajaan skripsi.
9. Teman – teman mahasiswa stambuk 2011 Departemen Teknik Mesin Fakultas
Teknik Universitas Sumatera Utara
10. Keluarga besar IMKA (Ikatan Mahasiswa Karo) PANDE KALIAGA FTUSU yang telah memberikan semangat kepada penulis selama berkuliah di
Departemen Teknik Mesin Fakultas Teknik Universitas Sumatera Utara.
11. Keluarga besar Pemuda/I Juhar Medan-Sekitarnya (PPJ-MS) yang telah
memberikan dukungan kepada penulis selama kuliah di Departemen Teknik
Mesin Fakultas Teknik Universitas Sumatera Utara.
12. Semua pihak yang telah banyak membantu penulis dalam menyelesaikan
skripsi ini.
Dengan demikian, penulisan skripsi ini ditulis dengan apa adanya, oleh karena
itu penulis mengharapkan kritik dan saran yang bersifat membangun agar kedepannya
dapat lebih baik lagi.
Dengan doa dan harapan dari penulis, semoga tulisan ini memberikan manfaat
kepada pembaca. Akhir kata penulis ucapkan banyak terima kasih dan Tuhan
memberkati.
Medan, Mei 2016
Penulis,
Roys A. Tarigan
NIM : 110401058
Universitas Sumatera Utara
ABSTRAK
Losses dapat mengurangi efektifitas penggunaan peralatan dalam kegiatan proses
produksi. Untuk mengetahui dan meminimumkan losses yang terjadi, diperlukan
adanya evaluasi kinerja dari peralatan produksi. Mesin Injection Molding adalah
salah satu jenis mesin yang digunakan dalam proses produksi di PT. Tirta
Sibayakindo yang akan dievaluasi efektifitasnya. Pengukuran efektifitas mesin
injection molding dapat dilakukan dengan menggunakan metode Overall Equipment
Effectiveness untuk mencegah terjadi 6 kerugian besar (Six Big Losses) yaitu,
breakdown losses, setup and adjusment losses, idling and minor stoppages losse,
reduced speed losses, rework losses dan yield scrap losses. Dalam perhitungan, OEE
mengukur efektifitas dengan menggunakan tiga sudut pandang untuk
mengidentifikasi six big losses, yaitu availability, performance dan quality.Dari hasil
pengolahan data, didapat nilai rata – rata OEE pada periode Maret 2015 – Maret 2016
adalah 75.94 %. Nilai Breakdown losses sebesar 1.47 %, hasil setup and adjusment
losses sebesar 1.37 % , hasil Idling and minor stoppages Losses sebesar 8.24 %, hasil
Reduced speed Losses sebesar 20.43 % , hasil Rework losses dan Yield / scrap losses
sebesar 0 %.
Kata Kunci: Availability, Quality,Performance, OEE, Six Big Losses
Universitas Sumatera Utara
ABSTRACT
Losses can reduce the effectiveness of the use of equipment in the production process.
To know and to minimize losses that occur, there needs to evaluate the performance
of the production equipment. Injection Molding Machine is one type of machines used
in the production process in PT. Tirta Sibayakindo be evaluated effectiveness.
Measurement of the effectiveness of the injection molding machine can be
accomplished by using the Overall Equipment Effectiveness to prevent it from
occurring 6 big losses (Six Big Losses), ie, breakdown losses, setup and adjustment
losses, idling and minor stoppages losse, reduced speed losses, rework losses and
yield scrap losses , In the calculation, OEE measures the effectiveness of using three
viewpoints to identify the six big losses, namely availability, performance and quality.
From the data processing, obtained value - average OEE in the period March 2015 March 2016 is 75.94%. Value Breakdown losses amounted 1.47%, the result of setup
and adjustment losses at 1.37%, results Idling and minor stoppages% Losses at 8.24,
the results Reduced speed Losses at 20.43%, results Rework losses and Yield / scrap
losses amounted to 0%.
Keywords: Availability, Quality, Performance, OEE, Six Big Losses
Universitas Sumatera Utara
DAFTAR ISI
KATA PENGANTAR ....................................................................................... i
ABSTRAK ........................................................................................................ iii
DAFTAR ISI ...................................................................................................... v
DAFTAR GAMBAR ....................................................................................... viii
DAFTAR TABEL ............................................................................................. ix
DAFTAR RUMUS ............................................................................................ x
BAB I PENDAHULUAN
1.1 Latar Belakang ............................................................................................. 1
1.2 Tujuan Penelitian ......................................................................................... 2
1.3 Pembatasan Masalah .................................................................................... 3
1.4 Manfaat Penelitian ....................................................................................... 3
1.5 Sistematika Penulisan .................................................................................. 4
BAB II MESIN INJECTION MOLDING
2.1 Mesin Injection Molding .............................................................................. 5
2.1.1 Langkah-Langkah Injection Molding .................................................... 6
2.1.2. Komponen-komponen Utama Sistem Injection Molding ..................... 7
2.1.2.1 Mold Clamp Unit ........................................................................... 8
2.1.2.2 Injection Unit ................................................................................. 12
2.1.3 Komponen Pendukung Mesin Injeksi ................................................... 14
2.1.4 Parameter-parameter Proses Injection Molding .................................. 15
2.1.5. Jenis-jenis Analisa Moldflow Plastic Insight ...................................... 16
2.1.6. Pengertian Plastik dalam Desain Plastik Molding .............................. 17
2.1.7. Prinsip Umum Desain Mold ............................................................... 18
2.1.8. Cacat Produksi Pada Proses Injeksi Plastik ........................................ 18
Universitas Sumatera Utara
BAB III TEORI PERAWATAN (MAINTENANCE)
3.1 Maintenance (Perawatan) ............................................................................ 22
3.1.1 Pengertian Maintenance ........................................................................ 22
3.1.2 Tujuan Maintenance .............................................................................. 23
3.1.3 Fungsi Pemeliharaan ............................................................................. 25
3.1.4 Jenis-Jenis Maintenance ........................................................................ 25
3.1.5 Konsep-Konsep Pemeliharaan .............................................................. 32
3.2 Total Productive Maintenance (TPM) ........................................................ 34
3.2.1 Sejarah TPM ......................................................................................... 34
3.2.2 Pengertian Total Productive Maintenance ............................................ 35
3.2.3 Tujuan Total Productive Maintenance .................................................. 38
3.2.4 Manfat Total Productive Maintenance .................................................. 39
3.2.5 Tahapan Penerapan TPM ...................................................................... 39
3.3 Analisa Produktivitas :Six Big Losses (6 Kerugian Besar) ......................... 40
3.4 Overall Equipment Effectiveness (OEE) .................................................... 42
3.4.1 Pengertian OEE ..................................................................................... 42
3.4.2 Tujuan OEE........................................................................................... 43
3.4.3 Perhitungan OEE................................................................................... 44
3.5 Diagram Sebab Akibat ............................................................................... 47
BAB IV METODE PENELITIAN
4.1 Tempat dan Waktu penelitian ..................................................................... 48
4.1.1
Tempat penelitian ............................................................................... 48
4.1.2
Waktu Penelitian ................................................................................ 48
4.2 Rancangan Penelitian .................................................................................. 48
4.3 Objek Penelitian ......................................................................................... 48
4.4 Instrumen Penelitian ................................................................................... 48
4.5 Pelaksanaan Penelitian ............................................................................... 49
4.6 Pengolahan Data ......................................................................................... 50
4.7 Analisis dan Pemecahan Masalah ............................................................... 51
Universitas Sumatera Utara
BAB V PENGOLAHAN DATA
5.1 Pengumpulan Data ...................................................................................... 52
5.2 Pengolahan Data.......................................................................................... 55
5.2.1 Perhitungan Availabilty ........................................................................ 55
5.2.2 Perhitungan Performance Efficiency .................................................... 57
5.2.3 Perhitungan Rate of Quality .................................................................. 59
5.2.4 Perhitungan OEE................................................................................... 61
5.2.5 Perhitungan OEE : Six Big Losses........................................................ 63
5.2.5.1 Downtime Losses ............................................................................ 63
5.2.5.2 Speed Losse..................................................................................... 65
5.2.5.3 Defect Losses .................................................................................. 67
BAB VI DISKUSI DAN PEMECAHAN MASALAH
6.1 Analisa Perhitungan OEE ........................................................................... 69
6.2 Analisa Perhitungan OEE : Six Big Losses ................................................ 70
6.3 Analisa Diagram Sebab Akibat ................................................................... 71
6.4 Usulan Penyelesaian Masalah ..................................................................... 73
6.4.1 Usulan Penyelesaian Masalah Six Big Losses ...................................... 73
6.4.2 Penerapan Total Productive Maintenance ............................................. 74
BAB VII KESIMPULAN DAN SARAN
6.1 Kesimpulan ................................................................................................. 75
6.2 Saran............................................................................................................ 76
DAFTAR PUSTAKA ...................................................................................... 77
LAMPIRAN ..................................................................................................... 79
Universitas Sumatera Utara
DAFTAR GAMBAR
Gambar 2.1 Proses mold .................................................................................... 6
Gambar 2.2 Injection unit dan clamping unit..................................................... 7
Gambar 2.3 Mold tipe dua plate......................................................................... 9
Gambar 2.4 Mold tipe tiga plate ....................................................................... 10
Gambar 2.5 Bagian – bagian injection molding................................................ 14
Gambar 2.6 Panel control.................................................................................. 14
Gambar 3.1 Delapan (8) Pilar TPM .................................................................. 38
Gambar 3.2 Model OEE.................................................................................... 43
Gambar 4.1 Diagram Alir Penelitian ................................................................ 51
Gambar 5.1 Grafik nilai availability injection molding .................................... 57
Gambar 5.2 Grafik nilai performance injection molding .................................. 59
Gambar 5.3 Grafik nilai Quality injection molding .......................................... 61
Gambar 5.4 Grafik nilai OEE injection molding .............................................. 62
Gambar 6.1 Diagram persentase Six Big Losses .............................................. 71
Gambar 6.2 Diagram fishbone mesin injection molding..................................72
Universitas Sumatera Utara
DAFTAR TABEL
Tabel 3.1 Six big losses dan perhitungan OEE ...............................................
Tabel 3.2 Standar OEE ....................................................................................
Tabel 5.1 Data waktu breakdown dan Setup pada
mesinInjection Molding ..................................................................
Tabel 5.2 Data waktu pemeliharaan (planned downtime)
mesin Injection Molding .................................................................
Tabel 5.3 Data produksi mesin injection molding
periode Maret 2015 – Maret 2016 ...................................................
Tabel 5.4 Nilai Availabilitymesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.5 Nilai Performance Effeciency mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.6 Nilai Rate of Quality Productmesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.7 Nilai Overall Equipment Effectiveness (OEE)
mesin injection molding periode Mar 2015 – Mar 2016.................
Tabel 5.8 Nilai Breakdown losses mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.9 Nilai Setup and Adjusment losses mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 5.10 Nilai Idling and Minor Stoppages losses mesin
injection molding periode Mar 2015 – Mar 2016 ...........................
Tabel 5.11 NilaiReduced Speedlosses mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 6.1 Persentase pencapaian mesin injection molding
periode Mar 2015 – Mar 2016 ........................................................
Tabel 6.2 Persentase faktor Six Big Losses mesin injection molding
periode Maret 2015 – Maret 2016 ...................................................
Tabel 6.3 Usulan Penyelesaian Masalah .........................................................
44
47
53
54
55
56
58
60
62
63
64
66
67
69
70
73
Universitas Sumatera Utara
DAFTAR RUMUS
Rumus 3.1
Rumus 3.2
Rumus 3.3
Rumus 3.4
Rumus 3.5
Rumus 3.6
Rumus 3.7
Rumus 3.8
Rumus 3.9
Rumus 3.10
Rumus 3.11
Rumus 3.12
Rumus 3.13
Rumus 3.14
Rumus 3.15
Rumus 3.16
Rumus 3.17
Breakdown Losses .............................................................................
Setup and Adjustment Losses ............................................................
Idling and Minor Stoppages Losses ...................................................
Reduced Speed Losses .......................................................................
Rework Losses ...................................................................................
Yield / Scrap Losses ...........................................................................
Nilai OEE ...........................................................................................
Nilai Availability................................................................................
Operation Time ..................................................................................
Loading Time .....................................................................................
Downtime ...........................................................................................
Performance Efficiency......................................................................
Operation Speed Rate.........................................................................
Net Operation Rate.............................................................................
Turunan Rumus Performance Efficiency ...........................................
Hasil Turunan Rumus Performance Efficiency .................................
Rate of Quality Product ......................................................................
40
41
41
41
41
42
44
44
45
45
45
45
46
46
46
46
46
Universitas Sumatera Utara