Studi Penerapan Total Productive Maintenance (TPM) Pada Mesin Pengaduk Ko-Kneader di Anode Green Plant PT. Indonesia Asahan Aluminium (Persero)
STUDI PENERAPAN TOTAL PRODUCTIVE MAINTENANCE(TPM)PADA
MESIN PENGADUKKO-KNEADERDI ANODE GREEN PLANT
PT. INDONESIA ASAHAN ALUMINIUM (Persero)
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi
Syarat Memperoleh Gelar Sarjana Teknik
FEBRI AGUSTINUS GINTING
110401111
DEPARTEMEN TEKNIK MESIN
FAKULTAS TEKNIK
UNIVERSITAS SUMATERA UTARA
2016
Universitas Sumatera Utara
ABSTRAK
Total Productive Maintenance (TPM) merupakan ide Nakajima (1988) yang
menekankan pada pendayagunaan dan keterlibatan sumber daya manusia dan
sistem Preventive Maintenance untuk memaksimalkan efektifitas peralatan
dengan melibatkan semua departemen dan fungsional organisasi. Studi penerapan
TPM di Pabrik Anoda Karbon PT. INALUM (Persero)
ini bertujuan untuk
mengukur efektifitas mesin pengaduk KO-Kneader dengan metode Overall
Equipment Effectiveness (OEE) yang kemudian dilanjutkan dengan pengukuran
Six Big Losses untuk mengetahui besarnya efisiensi yang hilang pada keenam
faktor Six Big Losses. Dengan diagram cause and effect dapat dianalisa masalah
sebenarnya yang menjadi penyebab utama tingginya kerugian dan rendahnya
efisiensi mesin. Hasil dan kesimpulan yang didapat adalah nilai OEE untuk
periode April 2015 – Maret 2016 berkisar 68% sampai 69%. Kondisi ini
menunjukkan kemampuan mesin pengaduk KO-Kneader dalam pencapaian
efektivitas penggunaan mesin belum mencapai kondisi yang ≥85%).
ideal (
Adapun yang mempengaruhi nilai OEE dan menjadi prioritas utama yang
direkomendasikan untuk dieliminasi perusahan adalah faktor Idling/Minor
Stoppages Losses sebesar 43,06% dan Reduce Speed Losses sebesar 31,41 %.
Kata kunci : Availability, Performance Efficiency, Rate of Quality Product, Overall Equipment
Efectiveness, Six Big Losses.
i
Universitas Sumatera Utara
ABSTRACT
Total Productive Maintenance (TPM) is an idea of Nakajima (1988), which
emphasizes the empowerment and involvement of human resources and
Preventive Maintenance System to maximize the effectiveness of the equipment by
involving all departments and functional organization. Study of the application of
TPM in Anode Green Plant at PT. INALUM (Persero) is intended to measure the
effectiveness of KO-Kneader mixer with the method of Overall Equipment
Effectiveness (OEE), followed by measuringthe Six Big Losses to know how much
efficiency lost from the six factors of Six Big Losses. With the cause and effect
diagram can be analyzed the real problem asthe major cause of high losses and
low efficiency of the engine. The results and conclusions obtained are OEE values
for the period of April 2015 - March 2016 ranges from 68% to 69%. This
indicates the ability of KO-Kneader mixer in achieving effective use of the engine
has not reached the ideal condition (≥85%). Factors that affecting the OEE value
and most priority for the company to be eliminated are, the Idling / Minor
Stoppages Losses factor amounted to 43.06% and Reduce Speed Losses factor
amounted to 31.41%.
Keywords : Availability, Performance Efficiency, Rate of Quality Product, Overall Equipment
Efectiveness, Six Big Losses.
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Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis panjatkan kehadirat Tuhan Yang Maha Esa atas
berkat – berkat yang berlimpah dan penyertaan-Nya penulis dapat menyelesaikan
skripsi ini dengan baik pada waktu yang tepat, dimana skripsi ini disusun untuk
memenuhi syarat kelulusan Strata 1 (S1) di Departemen Teknik Mesin, Fakultas
Teknik, Universitas Sumatera Utara.
Skripsi ini berjudul “STUDI PENERAPAN TOTAL PRODUCTIVE
MAINTENANCE (TPM)PADA MESIN PENGADUK KO-KNEADER DI
ANODE GREEN PLANT PT. INALUM (Persero)”.
Penulis banyak
mengalami hambatan dan tantangan dalam penulisan dan penyusunan skripsi ini,
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.
Selesainya skripsi ini tidak luput dari doa, dukungan, dorongan, dan
bantuan dari berbagai pihak. Oleh karena itu dengan ketulusan dan kerendahan
hati penulis 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. Kedua orang tua penulis, Bapak Anwar J P Ginting dan Ibu Bujuria br
Karosekali yang memberikan dukungan penuh dalam kasih sayang, doa –
doa dan materil.
5. Saudara kandung penulis, abangdaDesmon Abdi Jekri Ginting dan
keluarga, adindaMeilyn Fransiska Ginting, beserta seluruh keluarga yang
tidak bisa disebutkan satu persatu.
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Universitas Sumatera Utara
6. Rekan seperjuangan dalam penelitian saudara Trabanasia Therah Sitorus
yang telah berbagi waktu dan pemikiran selama proses pengerajaan
skripsi.
7. Teman – teman mahasiswa stambuk 2011 Departemen Teknik Mesin
Fakultas Teknik Universitas Sumatera Utara
8. Keluarga besar Pengurus KlasisPermata GBKP Binjai Langkat (Periode
2013-2016) dan Permata Khairos Runggun Paya Bakung yang selalu
mendukung dan mendoakan penulis.
Dengan doa dan harapan dari penulis, semoga tulisan ini memberikan manfaat
kepada pembaca. Akhir kata penulis ucapkan banyak terima kasih dan Tuhan
memberkati.
Medan,Agustus 2016
Febri Agustinus G
Nim : 110401111
iv
Universitas Sumatera Utara
DAFTAR ISI
ABSTRAK ...................................................................................................... i
KATA PENGANTAR .................................................................................... iii
DAFTAR ISI ................................................................................................... v
DAFTAR GAMBAR ...................................................................................... viii
DAFTAR TABEL .......................................................................................... x
DAFTAR PERSAMAAN............................................................................... xii
DAFTAR NOTASI ......................................................................................... xiii
BAB I PENDAHULUAN
1.1 Latar belakang ................................................................................ 1
1.2 Permasalahan .................................................................................. 2
1.3Tujuan Penelitian............................................................................. 2
1.4 Batasan Masalah Penelitian ............................................................ 2
1.5 Tujuan Penelitian............................................................................ 2
1.6Manfaat Penelitian........................................................................... 3
1.7 Sistematika Penulisan ..................................................................... 3
BAB II MESIN PENGADUK KO-KNEADER
2.1 Proses Produksi Aluminium .......................................................... 5
2.2 Pabrik Anoda Karbon ..................................................................... 6
2.2.1. Mesin Pengaduk / KO-Kneader ............................................... 8
2.2.2. KO-Kneader di Anode Green Plant PT. INALUM ................. 9
2.2.3. Komponen Mesin Pengaduk KO-Kneader .............................. 13
2.2.4. Karakteristik Operasi Mesin Pengaduk KO-Kneader .............. 17
2.3 Pabrik Reduksi ............................................................................... 18
2.3.1 Operasi Pot Reduksi .................................................................. 19
2.4 Pabrik Pencetakan .......................................................................... 21
BAB III LANDASAN TEORI
3.1. Total Productive Maintenance (TPM) .......................................... 22
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3.1.1. Pengertian Total Productive Maintenance (TPM)................... 22
3.1.2. Manfaat dari Total Productive Maintenance (TPM) ............... 26
3.1.3. Analisis Produktivitas : Six Big Losses (6 Kerugian Besar) .... 27
3.1.4. OEE (Overall Equipment Effectiveness).................................. 33
BAB IV METODE PENELITIAN
4.1 Tempat dan Waktu Penelitian ........................................................ 34
4.1.1 Tempat Penelitan ...................................................................... 34
4.1.2 Waktu Penelitian ....................................................................... 34
4.2 Rancangan Penelitian ..................................................................... 34
4.3 Objek Penelitian ............................................................................. 34
4.4 Instrumen Penelitian ....................................................................... 35
4.5 Pelaksanaan Penelitian ................................................................... 36
4.6 Pengolahan Data ............................................................................. 37
4.7 Analisa Data dan Pemecahan Masalah ........................................... 38
BAB V ANALISA DATA
5.1. Pengumpulan Data ........................................................................ 41
5.1.1. Data waktu Planned Downtime ............................................... 41
5.1.2. Data Waktu Unplanned Downtime .......................................... 43
5.1.2.1Breakdown .......................................................................... 43
5.1.2.2 Setup .................................................................................. 43
5.1.3. Data Produksi ........................................................................... 45
5.2 Pengolahan Data ............................................................................. 46
5.2.1 Perhitungan nilaiAvalability (AV) ............................................. 47
5.2.2. Perhitungan Performance Efficiency(PE) ................................ 49
5.2.3. Perhitungan Rate Of Quality Product (RQP)........................... 51
5.2.4. Perhitungan Overall Equipment Effectiveness (OEE) ............. 53
5.2.5. Perhitungan Six Big Losses ...................................................... 55
5.2.5.1. Downtime Losess .............................................................. 55
5.2.5.2. Speed Loss ........................................................................ 59
5.2.5.3. Defect loss ........................................................................ 63
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5.3. Analisa Data .................................................................................. 66
5.3.1 Analisa Perhitungan Overall Equipment Effectiveness (OEE) 66
5.3.2 Analisis perhitungan OEE Six Big Losses................................ 67
5.4 Analisa diagram sebab akibat (Fish Bone Diagram) ..................... 70
5.5 Usulan pemecahan masalah ........................................................... 72
5.5.1 Usulan penyelesaian masalah Six Big Losses ........................... 72
5.5.2 Penerapan Total Productive Maintenance (TPM) .................... 73
BAB VI KESIMPULAN DAN SARAN
6.1 Kesimpulan..................................................................................... 74
6.2 Saran ............................................................................................... 75
DAFTAR PUSTAKA ..................................................................................... xiv
LAMPIRAN .................................................................................................... xv
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Universitas Sumatera Utara
DAFTAR GAMBAR
Gambar 2.1 : Pipa Penyalur Tar Pitch ......................................................................9
Gambar 2.2 : KO-Kneader - 201 ............................................................................10
Gambar 2.3 :Kokas.................................................................................................11
Gambar 2.4 :Coal Tar Pitch ...................................................................................11
Gambar 2.5 : Puntung/Butt.....................................................................................11
Gambar 2.6 :Pipa Penyalur Material Dari KO-Kneader – 201 ..............................12
Gambar 2.7 :Ko-Kneader 202 ................................................................................12
Gambar 2.8 : Motor KO-Kneader ..........................................................................13
Gambar 2.9 : Pandangan Atas Gear Box ...............................................................14
Gambar 2.10 :Rigit Kopling...................................................................................15
Gambar 2.11 :Pompa Oli Pelumas .........................................................................16
Gambar 2.12 :Kneading Shaft ................................................................................16
Gambar 2.13 :Teeth ................................................................................................17
Gambar 2.14 : Prinsip Kinerja BUSS Kneader ......................................................18
Gambar 3.1 :8 Pilar dalam TPM ............................................................................24
Gambar 3.2 :Overall Equipment Effectiveness ......................................................28
Gambar 3.3 :World Class of OEE ..........................................................................33
Gambar 4.1 :Mesin Pengaduk KO-Kneader KN-201 ............................................35
Gambar 4.2 :Tahapan proses pemecahan masalah .................................................39
Gambar 4.3 :Diagram alir analisaOverall Equipment Effectiveness (OEE) ..........40
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Universitas Sumatera Utara
Gambar 5.1 :Diagram Unplanned Downtime Mesin Pengaduk KO-Kneader
Periode April 2015-Maret 2016. .......................................................44
Gambar 5.2 :Diagram Total Produksi Pasta periode April 2015 – Maret 2016. ....46
Gambar 5.3 : Diagram Nilai Availability Mesin Pengaduk KO-Kneader. .............49
Gambar 5.4 :Diagram Performance efficiency.......................................................51
Gambar 5.5 :Diagram Rate of Quality Product. ....................................................53
Gambar 5.6 :Diagram Overall Equipment Effectivenes .........................................55
Gambar 5.7 :Diagram Equipment Failure/Breakdown Lossperiode April 2015 Maret 2016 ........................................................................................57
Gambar 5.8 :Diagram Setup and Adjustment losses periode April 2015 –
Maret 2016 ........................................................................................59
Gambar 5.9 :Diagram Idling and Minor Stoppages Lossesperiode April 2015 Maret 2016. .......................................................................................61
Gambar 5.10 :Diagram Reduce Speed LossesMesin Pengaduk KO-Kneader. ......63
Gambar 5.11 :Diagram Rework losses untuk periode
April 2015 –Maret 2016........ .................................................................................65
Gambar 5.12 :Grafik Perbandingan OEE Mesin Pengaduk KO-Kneader
periode April 2015-Maret 2016 dengan Standar JIPM
(Japan Institute of Plant Maintenance) ..........................................67
Gambar 5.13 :Diagram persentase Six Big Losses. ................................................68
Gambar 5.14 :Diagram Sebab Akibat (Fish Bone) ................................................70
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Universitas Sumatera Utara
DAFTAR TABEL
Tabel 2.1. Kadar Bahan Antara Tar pith, Kokas dan Butt
di KO-Kneader – 201 ........................................................................10
Tabel 5.1. Data Planned Downtime Mesin Pengaduk KO-Kneader Periode
April 2015 - Maret 2016 ........................................................................42
Tabel 5.2. Data Unplanned DowntimeMesin Pengaduk KO-Kneader ..................43
Tabel 5.3.Data Produksi Pasta periode April 2015 – Maret 2016 .........................45
Tabel 5.4. World Class OEE ..................................................................................47
Tabel 5.5.Availability (AV) Mesin Pengaduk KO-Kneader periode
2015-2016 ..............................................................................................48
Tabel 5.6.Performance Efficiency periode April 2015 - Maret 2016. ...................50
Tabel 5.7. Rate of Quality Product periode April 2015-Maret 2016 .....................52
Tabel 5.8. Nilai Overall Equipment Effectivenesmesin pengaduk KO-Kneader
periode April 2015 - Maret 2016 ......................................................54
Tabel 5.9. Equipment Failure/Breakdowns (EF) periode April 2015Maret 2016 ........................................................................................56
Tabel 5.10. Setup and Adjustment losses Periode April 2015-Maret 2016 ............58
Tabel 5.11. Idling and Minor Stoppages Losses untuk periode April 2015 - Maret
2015. .................................................................................................60
Tabel 5.12. Reduce speed losses untuk periode April 2015 – Maret 2016. ...........62
Tabel 5.13. Rework losses untuk periode April 2015 –Maret 2016 .......................64
Tabel 5.14Persentase pencapaian mesin pengaduk KO-Kneader periode
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Universitas Sumatera Utara
April 2015 – Maret 2016 .......................................................................66
Tabel 5.15. Persentase Faktor Six Big LossesMesin Pengaduk KO-Kneader
periode April 2015 – Maret 2016 .....................................................68
Tabel 5.16.Six Big Losses Target ...........................................................................69
Tabel 5.17. Usulan penyelesaian masalah Six Big Losses .....................................72
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DAFTAR PERSAMAAN
Persamaan 2.1 :Gradien Kecepatan Pengadukan .....................................................9
Persamaan 3.1 : Overall Equipment Efectiveness (OEE).......................................29
Persamaan 3.2 : Availability (AV) .........................................................................29
Persamaan 3.3 : Loading Time ...............................................................................30
Persamaan 3.4 : Operation Time ............................................................................30
Persamaan 3.5 : Downtime .....................................................................................30
Persamaan 3.6 : Operation Speed Rate ..................................................................30
Persamaan 3.7 : Net Operation Rate ......................................................................31
Persamaan 3.8 : Performance Efficiency (PE) .......................................................31
Persamaan 3.9 : Rate of Quality Product (RQP)....................................................31
Persamaan 5.1 : Equipment Failure/Brealdowns (EF) ..........................................56
Persamaan 5.2 : Setup and Adjustment loss (SA) ..................................................57
Persamaan 5.3 : Idling and Minor Stoppages Losses (IMS) ..................................59
Persamaan 5.4 : Non Productive Time ...................................................................59
Persamaan 5.5 : Reduce Speed Losses(RS) ............................................................61
Persamaan 5.6 : Persentase total reject pasta .........................................................63
Persamaan 5.7 : Rework Loss (RL) ........................................................................64
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Universitas Sumatera Utara
DAFTAR NOTASI
P
= Suplai tenaga (N.m/s)
M
= Massa material yang diaduk (kg)
µ
= Viskositas absolut (N.s/m3)
v
= Kecepatan
KN
= KO-Kneader
SM
= Shaking Machine
PH
= Pre-Heater
AV
= Availability
PE
= Performance Efficiency
RQP
= Rate of Quality Product
OEE
= Overall Equipment Efectiveness
TPM
= Total Productive Maintenance
PM
= Planned Maintenance
EF
= Equipment Failure/Breakdown
SA
= Setup and Adjustment loss
IMS
= Idling and Minor Stoppages loss
RS
= Reduce Speed
RL
= Rework Loss
JIPM
= Japan Institute of Plant Maintenance
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Universitas Sumatera Utara
MESIN PENGADUKKO-KNEADERDI ANODE GREEN PLANT
PT. INDONESIA ASAHAN ALUMINIUM (Persero)
SKRIPSI
Skripsi Yang Diajukan Untuk Melengkapi
Syarat Memperoleh Gelar Sarjana Teknik
FEBRI AGUSTINUS GINTING
110401111
DEPARTEMEN TEKNIK MESIN
FAKULTAS TEKNIK
UNIVERSITAS SUMATERA UTARA
2016
Universitas Sumatera Utara
ABSTRAK
Total Productive Maintenance (TPM) merupakan ide Nakajima (1988) yang
menekankan pada pendayagunaan dan keterlibatan sumber daya manusia dan
sistem Preventive Maintenance untuk memaksimalkan efektifitas peralatan
dengan melibatkan semua departemen dan fungsional organisasi. Studi penerapan
TPM di Pabrik Anoda Karbon PT. INALUM (Persero)
ini bertujuan untuk
mengukur efektifitas mesin pengaduk KO-Kneader dengan metode Overall
Equipment Effectiveness (OEE) yang kemudian dilanjutkan dengan pengukuran
Six Big Losses untuk mengetahui besarnya efisiensi yang hilang pada keenam
faktor Six Big Losses. Dengan diagram cause and effect dapat dianalisa masalah
sebenarnya yang menjadi penyebab utama tingginya kerugian dan rendahnya
efisiensi mesin. Hasil dan kesimpulan yang didapat adalah nilai OEE untuk
periode April 2015 – Maret 2016 berkisar 68% sampai 69%. Kondisi ini
menunjukkan kemampuan mesin pengaduk KO-Kneader dalam pencapaian
efektivitas penggunaan mesin belum mencapai kondisi yang ≥85%).
ideal (
Adapun yang mempengaruhi nilai OEE dan menjadi prioritas utama yang
direkomendasikan untuk dieliminasi perusahan adalah faktor Idling/Minor
Stoppages Losses sebesar 43,06% dan Reduce Speed Losses sebesar 31,41 %.
Kata kunci : Availability, Performance Efficiency, Rate of Quality Product, Overall Equipment
Efectiveness, Six Big Losses.
i
Universitas Sumatera Utara
ABSTRACT
Total Productive Maintenance (TPM) is an idea of Nakajima (1988), which
emphasizes the empowerment and involvement of human resources and
Preventive Maintenance System to maximize the effectiveness of the equipment by
involving all departments and functional organization. Study of the application of
TPM in Anode Green Plant at PT. INALUM (Persero) is intended to measure the
effectiveness of KO-Kneader mixer with the method of Overall Equipment
Effectiveness (OEE), followed by measuringthe Six Big Losses to know how much
efficiency lost from the six factors of Six Big Losses. With the cause and effect
diagram can be analyzed the real problem asthe major cause of high losses and
low efficiency of the engine. The results and conclusions obtained are OEE values
for the period of April 2015 - March 2016 ranges from 68% to 69%. This
indicates the ability of KO-Kneader mixer in achieving effective use of the engine
has not reached the ideal condition (≥85%). Factors that affecting the OEE value
and most priority for the company to be eliminated are, the Idling / Minor
Stoppages Losses factor amounted to 43.06% and Reduce Speed Losses factor
amounted to 31.41%.
Keywords : Availability, Performance Efficiency, Rate of Quality Product, Overall Equipment
Efectiveness, Six Big Losses.
ii
Universitas Sumatera Utara
KATA PENGANTAR
Puji dan syukur penulis panjatkan kehadirat Tuhan Yang Maha Esa atas
berkat – berkat yang berlimpah dan penyertaan-Nya penulis dapat menyelesaikan
skripsi ini dengan baik pada waktu yang tepat, dimana skripsi ini disusun untuk
memenuhi syarat kelulusan Strata 1 (S1) di Departemen Teknik Mesin, Fakultas
Teknik, Universitas Sumatera Utara.
Skripsi ini berjudul “STUDI PENERAPAN TOTAL PRODUCTIVE
MAINTENANCE (TPM)PADA MESIN PENGADUK KO-KNEADER DI
ANODE GREEN PLANT PT. INALUM (Persero)”.
Penulis banyak
mengalami hambatan dan tantangan dalam penulisan dan penyusunan skripsi ini,
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.
Selesainya skripsi ini tidak luput dari doa, dukungan, dorongan, dan
bantuan dari berbagai pihak. Oleh karena itu dengan ketulusan dan kerendahan
hati penulis 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. Kedua orang tua penulis, Bapak Anwar J P Ginting dan Ibu Bujuria br
Karosekali yang memberikan dukungan penuh dalam kasih sayang, doa –
doa dan materil.
5. Saudara kandung penulis, abangdaDesmon Abdi Jekri Ginting dan
keluarga, adindaMeilyn Fransiska Ginting, beserta seluruh keluarga yang
tidak bisa disebutkan satu persatu.
iii
Universitas Sumatera Utara
6. Rekan seperjuangan dalam penelitian saudara Trabanasia Therah Sitorus
yang telah berbagi waktu dan pemikiran selama proses pengerajaan
skripsi.
7. Teman – teman mahasiswa stambuk 2011 Departemen Teknik Mesin
Fakultas Teknik Universitas Sumatera Utara
8. Keluarga besar Pengurus KlasisPermata GBKP Binjai Langkat (Periode
2013-2016) dan Permata Khairos Runggun Paya Bakung yang selalu
mendukung dan mendoakan penulis.
Dengan doa dan harapan dari penulis, semoga tulisan ini memberikan manfaat
kepada pembaca. Akhir kata penulis ucapkan banyak terima kasih dan Tuhan
memberkati.
Medan,Agustus 2016
Febri Agustinus G
Nim : 110401111
iv
Universitas Sumatera Utara
DAFTAR ISI
ABSTRAK ...................................................................................................... i
KATA PENGANTAR .................................................................................... iii
DAFTAR ISI ................................................................................................... v
DAFTAR GAMBAR ...................................................................................... viii
DAFTAR TABEL .......................................................................................... x
DAFTAR PERSAMAAN............................................................................... xii
DAFTAR NOTASI ......................................................................................... xiii
BAB I PENDAHULUAN
1.1 Latar belakang ................................................................................ 1
1.2 Permasalahan .................................................................................. 2
1.3Tujuan Penelitian............................................................................. 2
1.4 Batasan Masalah Penelitian ............................................................ 2
1.5 Tujuan Penelitian............................................................................ 2
1.6Manfaat Penelitian........................................................................... 3
1.7 Sistematika Penulisan ..................................................................... 3
BAB II MESIN PENGADUK KO-KNEADER
2.1 Proses Produksi Aluminium .......................................................... 5
2.2 Pabrik Anoda Karbon ..................................................................... 6
2.2.1. Mesin Pengaduk / KO-Kneader ............................................... 8
2.2.2. KO-Kneader di Anode Green Plant PT. INALUM ................. 9
2.2.3. Komponen Mesin Pengaduk KO-Kneader .............................. 13
2.2.4. Karakteristik Operasi Mesin Pengaduk KO-Kneader .............. 17
2.3 Pabrik Reduksi ............................................................................... 18
2.3.1 Operasi Pot Reduksi .................................................................. 19
2.4 Pabrik Pencetakan .......................................................................... 21
BAB III LANDASAN TEORI
3.1. Total Productive Maintenance (TPM) .......................................... 22
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3.1.1. Pengertian Total Productive Maintenance (TPM)................... 22
3.1.2. Manfaat dari Total Productive Maintenance (TPM) ............... 26
3.1.3. Analisis Produktivitas : Six Big Losses (6 Kerugian Besar) .... 27
3.1.4. OEE (Overall Equipment Effectiveness).................................. 33
BAB IV METODE PENELITIAN
4.1 Tempat dan Waktu Penelitian ........................................................ 34
4.1.1 Tempat Penelitan ...................................................................... 34
4.1.2 Waktu Penelitian ....................................................................... 34
4.2 Rancangan Penelitian ..................................................................... 34
4.3 Objek Penelitian ............................................................................. 34
4.4 Instrumen Penelitian ....................................................................... 35
4.5 Pelaksanaan Penelitian ................................................................... 36
4.6 Pengolahan Data ............................................................................. 37
4.7 Analisa Data dan Pemecahan Masalah ........................................... 38
BAB V ANALISA DATA
5.1. Pengumpulan Data ........................................................................ 41
5.1.1. Data waktu Planned Downtime ............................................... 41
5.1.2. Data Waktu Unplanned Downtime .......................................... 43
5.1.2.1Breakdown .......................................................................... 43
5.1.2.2 Setup .................................................................................. 43
5.1.3. Data Produksi ........................................................................... 45
5.2 Pengolahan Data ............................................................................. 46
5.2.1 Perhitungan nilaiAvalability (AV) ............................................. 47
5.2.2. Perhitungan Performance Efficiency(PE) ................................ 49
5.2.3. Perhitungan Rate Of Quality Product (RQP)........................... 51
5.2.4. Perhitungan Overall Equipment Effectiveness (OEE) ............. 53
5.2.5. Perhitungan Six Big Losses ...................................................... 55
5.2.5.1. Downtime Losess .............................................................. 55
5.2.5.2. Speed Loss ........................................................................ 59
5.2.5.3. Defect loss ........................................................................ 63
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5.3. Analisa Data .................................................................................. 66
5.3.1 Analisa Perhitungan Overall Equipment Effectiveness (OEE) 66
5.3.2 Analisis perhitungan OEE Six Big Losses................................ 67
5.4 Analisa diagram sebab akibat (Fish Bone Diagram) ..................... 70
5.5 Usulan pemecahan masalah ........................................................... 72
5.5.1 Usulan penyelesaian masalah Six Big Losses ........................... 72
5.5.2 Penerapan Total Productive Maintenance (TPM) .................... 73
BAB VI KESIMPULAN DAN SARAN
6.1 Kesimpulan..................................................................................... 74
6.2 Saran ............................................................................................... 75
DAFTAR PUSTAKA ..................................................................................... xiv
LAMPIRAN .................................................................................................... xv
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DAFTAR GAMBAR
Gambar 2.1 : Pipa Penyalur Tar Pitch ......................................................................9
Gambar 2.2 : KO-Kneader - 201 ............................................................................10
Gambar 2.3 :Kokas.................................................................................................11
Gambar 2.4 :Coal Tar Pitch ...................................................................................11
Gambar 2.5 : Puntung/Butt.....................................................................................11
Gambar 2.6 :Pipa Penyalur Material Dari KO-Kneader – 201 ..............................12
Gambar 2.7 :Ko-Kneader 202 ................................................................................12
Gambar 2.8 : Motor KO-Kneader ..........................................................................13
Gambar 2.9 : Pandangan Atas Gear Box ...............................................................14
Gambar 2.10 :Rigit Kopling...................................................................................15
Gambar 2.11 :Pompa Oli Pelumas .........................................................................16
Gambar 2.12 :Kneading Shaft ................................................................................16
Gambar 2.13 :Teeth ................................................................................................17
Gambar 2.14 : Prinsip Kinerja BUSS Kneader ......................................................18
Gambar 3.1 :8 Pilar dalam TPM ............................................................................24
Gambar 3.2 :Overall Equipment Effectiveness ......................................................28
Gambar 3.3 :World Class of OEE ..........................................................................33
Gambar 4.1 :Mesin Pengaduk KO-Kneader KN-201 ............................................35
Gambar 4.2 :Tahapan proses pemecahan masalah .................................................39
Gambar 4.3 :Diagram alir analisaOverall Equipment Effectiveness (OEE) ..........40
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Gambar 5.1 :Diagram Unplanned Downtime Mesin Pengaduk KO-Kneader
Periode April 2015-Maret 2016. .......................................................44
Gambar 5.2 :Diagram Total Produksi Pasta periode April 2015 – Maret 2016. ....46
Gambar 5.3 : Diagram Nilai Availability Mesin Pengaduk KO-Kneader. .............49
Gambar 5.4 :Diagram Performance efficiency.......................................................51
Gambar 5.5 :Diagram Rate of Quality Product. ....................................................53
Gambar 5.6 :Diagram Overall Equipment Effectivenes .........................................55
Gambar 5.7 :Diagram Equipment Failure/Breakdown Lossperiode April 2015 Maret 2016 ........................................................................................57
Gambar 5.8 :Diagram Setup and Adjustment losses periode April 2015 –
Maret 2016 ........................................................................................59
Gambar 5.9 :Diagram Idling and Minor Stoppages Lossesperiode April 2015 Maret 2016. .......................................................................................61
Gambar 5.10 :Diagram Reduce Speed LossesMesin Pengaduk KO-Kneader. ......63
Gambar 5.11 :Diagram Rework losses untuk periode
April 2015 –Maret 2016........ .................................................................................65
Gambar 5.12 :Grafik Perbandingan OEE Mesin Pengaduk KO-Kneader
periode April 2015-Maret 2016 dengan Standar JIPM
(Japan Institute of Plant Maintenance) ..........................................67
Gambar 5.13 :Diagram persentase Six Big Losses. ................................................68
Gambar 5.14 :Diagram Sebab Akibat (Fish Bone) ................................................70
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DAFTAR TABEL
Tabel 2.1. Kadar Bahan Antara Tar pith, Kokas dan Butt
di KO-Kneader – 201 ........................................................................10
Tabel 5.1. Data Planned Downtime Mesin Pengaduk KO-Kneader Periode
April 2015 - Maret 2016 ........................................................................42
Tabel 5.2. Data Unplanned DowntimeMesin Pengaduk KO-Kneader ..................43
Tabel 5.3.Data Produksi Pasta periode April 2015 – Maret 2016 .........................45
Tabel 5.4. World Class OEE ..................................................................................47
Tabel 5.5.Availability (AV) Mesin Pengaduk KO-Kneader periode
2015-2016 ..............................................................................................48
Tabel 5.6.Performance Efficiency periode April 2015 - Maret 2016. ...................50
Tabel 5.7. Rate of Quality Product periode April 2015-Maret 2016 .....................52
Tabel 5.8. Nilai Overall Equipment Effectivenesmesin pengaduk KO-Kneader
periode April 2015 - Maret 2016 ......................................................54
Tabel 5.9. Equipment Failure/Breakdowns (EF) periode April 2015Maret 2016 ........................................................................................56
Tabel 5.10. Setup and Adjustment losses Periode April 2015-Maret 2016 ............58
Tabel 5.11. Idling and Minor Stoppages Losses untuk periode April 2015 - Maret
2015. .................................................................................................60
Tabel 5.12. Reduce speed losses untuk periode April 2015 – Maret 2016. ...........62
Tabel 5.13. Rework losses untuk periode April 2015 –Maret 2016 .......................64
Tabel 5.14Persentase pencapaian mesin pengaduk KO-Kneader periode
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April 2015 – Maret 2016 .......................................................................66
Tabel 5.15. Persentase Faktor Six Big LossesMesin Pengaduk KO-Kneader
periode April 2015 – Maret 2016 .....................................................68
Tabel 5.16.Six Big Losses Target ...........................................................................69
Tabel 5.17. Usulan penyelesaian masalah Six Big Losses .....................................72
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DAFTAR PERSAMAAN
Persamaan 2.1 :Gradien Kecepatan Pengadukan .....................................................9
Persamaan 3.1 : Overall Equipment Efectiveness (OEE).......................................29
Persamaan 3.2 : Availability (AV) .........................................................................29
Persamaan 3.3 : Loading Time ...............................................................................30
Persamaan 3.4 : Operation Time ............................................................................30
Persamaan 3.5 : Downtime .....................................................................................30
Persamaan 3.6 : Operation Speed Rate ..................................................................30
Persamaan 3.7 : Net Operation Rate ......................................................................31
Persamaan 3.8 : Performance Efficiency (PE) .......................................................31
Persamaan 3.9 : Rate of Quality Product (RQP)....................................................31
Persamaan 5.1 : Equipment Failure/Brealdowns (EF) ..........................................56
Persamaan 5.2 : Setup and Adjustment loss (SA) ..................................................57
Persamaan 5.3 : Idling and Minor Stoppages Losses (IMS) ..................................59
Persamaan 5.4 : Non Productive Time ...................................................................59
Persamaan 5.5 : Reduce Speed Losses(RS) ............................................................61
Persamaan 5.6 : Persentase total reject pasta .........................................................63
Persamaan 5.7 : Rework Loss (RL) ........................................................................64
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DAFTAR NOTASI
P
= Suplai tenaga (N.m/s)
M
= Massa material yang diaduk (kg)
µ
= Viskositas absolut (N.s/m3)
v
= Kecepatan
KN
= KO-Kneader
SM
= Shaking Machine
PH
= Pre-Heater
AV
= Availability
PE
= Performance Efficiency
RQP
= Rate of Quality Product
OEE
= Overall Equipment Efectiveness
TPM
= Total Productive Maintenance
PM
= Planned Maintenance
EF
= Equipment Failure/Breakdown
SA
= Setup and Adjustment loss
IMS
= Idling and Minor Stoppages loss
RS
= Reduce Speed
RL
= Rework Loss
JIPM
= Japan Institute of Plant Maintenance
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