TUGAS AKHIR SKRIPSI
PENENTUAN INTERVAL PERAWATAN MESIN BUCKET ELEVATOR
PADA KOMPONEN CHAIN DENGAN METODE ANALISA
KEANDALAN DI PT. SEMEN INDONESIA TBK.
DisusunOleh :
Kukuh Prabowo
09540069
JURUSAN TEKNIK INDUSTRI
FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH MALANG
2015
KATA PENGANTAR
SyukurAlhamdulillah kami haturkankehadirat Allah Subhanahuwata’
alaatasrahmatNyasehinggamakalah penelitian
inidapatterselesaikandenganlancartanpaadanyasuatuhalangan yang berarti.
Keberhasilanpenulisanmakalah penelitian
initentunyatidaklepasdariberbagaipihak yang
senantiasamemberikanbimbingandanpengarahanselamaini.Untukinipenulismenya
mpaikan rasa terimakasih yang sebesar-besarnyakepada :
1. Kedua Orang Tua (IbudanBapak) yang
tiadahentimemberikandukungansertado’atanpapernahdimintasertakakakda
nadik yang selalumemberikanperhatian, semangat,
do’adandukunganselamaini.
2. Bapak Ir. HM Kholik,MT. selakuDosenPembimbing I.
3. BapakM. Irwan Pambudhiarto,ST, MT. selakuDosenPembimbing II
4. BapakIlyasMas'udin, M.LogScm, Ph.DselakuDosen Penguji I.
5. Ibu Dian Palupy, ST, MT. selakuDosenPenguji II.
6. SeluruhBapak/IbuDosendan Tata Usaha,
JurusanTeknikIndustriFakultasTeknikUniversitasMuhammadiyah Malang.
7. Seluruhpihak di PT. SEMEN INDONESIATbk. Gresik.
8. Teman-teman yang selalu memberi semangat dan do’a
Dalampenulisanmakalah ini,
penelitiberusahasemaksimalmungkinuntukmemperolehhasil yang sebaik-
baiknya.Namundemikiankarenaketerbatasanpeneliti
sendiri,makalahinimasihbanyakkekurangandanmasihjauhdarikesempurnaan.
Untukitukritikdan saran sangatpeneliti
harapkangunaperbaikanpenulisanmakalahini.
Harapanpeneliti semoga makalah sederhanainidapat
bermanfaatdanbergunasebagaibahanpertimbangandalampenulisanpenelitian yang
serupa.Malang, 15 Mei 2015
DAFTAR ISI
ISI HALAMAN
LEMBAR JUDUL................................................................................................
LEMBAR PENGESAHAN..................................................................................
SURAT PERNYATAAN KEASLIAN...............................................................
BERITA ACARA UJIAN TUGAS AKHIR........................................................
LEMBAR BIMBINGAN TUGAS AKHIR.........................................................
SURAT KETERANGAN PENELITIAN...........................................................
KATA PENGANTAR.........................................................................................
ABSTRAKSI.......................................................................................................
DAFTAR ISI........................................................................................................
DAFTAR TABEL................................................................................................
DAFTAR GAMBAR...........................................................................................
DAFTAR LAMPIRAN........................................................................................
BAB I PENDAHULUAN
1.1 Latar Belakang................................................................................................
1.2 Rumusan Masalah...........................................................................................
1.3 Tujuan Penelitian............................................................................................
1.4 Manfaat Penelitian..........................................................................................
1.5 Batasan Masalah dan Asumsi.........................................................................
BAB II LANDASAN TEORI
2.1 Deskripsi Keandalan.......................................................................................
2.1.1 Model Matematis Keandalan...............................................................
2.1.2 Fungsi Keandalan.................................................................................
2.1.3 Mean Time To Failure (MTTF)...........................................................
2.1.4 Fungsi laju Kerusakan (Hazard Fungtion)...........................................
2.1.5 Fungsi Distribusi Kerusakan................................................................
2.1.6 Mean Time Between Failure (MTBF).................................................
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2.1.7 Kurva Laju Kerusakan.........................................................................
2.2 Pengertian Perawatan......................................................................................
2.2.1 Tujuan Perawatan.................................................................................
2.2.2 Jenis-Jenis Perawatan...........................................................................
2.2.2.1 Perawatan Terencana..............................................................
2.2.2.2 Perawatan Tidak Terencana....................................................
2.3 Pengujian Kecocokan Data.............................................................................
2.3.1 Pengujian Chi Square (Goodness of Fit)..............................................
2.4 Ketersediaan (Availabilty)..............................................................................
2.5 Biaya Perawatan dan Perbaikan......................................................................
2.6 Penentuan Interval waktu Perawatan..............................................................
2.7 Mesin Bucket elevator....................................................................................
BAB III METODOLOGI PENELITIAN
3.1 Flow Chart......................................................................................................
3.2 Survey Perusahaan..........................................................................................
3.3 Perumusan Masalah dan tujuan Masalah........................................................
3.4 Tinjauan Pustaka.............................................................................................
3.5 Metode Pengumpulan data dan Pengolahan Data...........................................
3.6 Pengumpulan Data..........................................................................................
3.6.1 Biaya Kerusakan..................................................................................
3.6.2 Biaya Perawatan Terencana.................................................................
3.7 Pengolahan dan Analisa Data.........................................................................
3.8 Analisa Pembahasan.......................................................................................
3.9 Kesimpulan dan Saran....................................................................................
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA
4.1 Tinjauan Perusahaan.......................................................................................
4.1.1 Profil Perusahaan.................................................................................
4.1.2 Proses Perusahaan................................................................................
4.1.2.1 Penyiapan Bahan Baku..............................................................
4.1.2.3 Crusher......................................................................................
4.1.2.4 Raw Mill....................................................................................
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4.1.2.5 Kiln (Pembakaran)....................................................................
4.1.2.6 Finish Mill.................................................................................
4.1.2.7 Pengisian (Packer).....................................................................
4.2 Pengumpulan Data..........................................................................................
4.2.1 Data Breakdown Mesin Grinding Mill................................................
4.2.2 Data Biaya............................................................................................
4.3 Pengolahan Data.............................................................................................
4.3.1 Penentuan Distribusi Data dan Parameter Keandalan..........................
4.3.2 Menentukan Fungsi Padat Probabilitas................................................
4.3.3 Tingkat Keandalan Mesin Bucket Elevator.........................................
4.3.4 Perhitungan Laju Kerusakan................................................................
4.3.5 Perhitungan MTTF, MTTR, MTBF.....................................................
4.3.6 Ketersediaan (Availability)..................................................................
4.3.7 Perhitungan Biaya................................................................................
4.3.8 Perhitungan Perbandingan Sebelum dan Sesudah Perbaikan..............
BAB V ANALISA DAN PEMBAHASAN
5.1 Analisa Data....................................................................................................
5.1.1 Analisa Pembahasan untuk Penentuan Parameter...............................
5.1.2 Analisa Fungsi Padat Probabilitas Distribusi Weibul..........................
5.1.3 Analisa Fungsi Laju Kerusakan...........................................................
5.1.4 Perhitungan MTTF, MTTR, MTBF....................................................
5.1.5 Ketersediaan (Availability)..................................................................
5.1.6 Perhitungan Biaya...............................................................................
BAB VI KESIMPULAN DAN SARAN
6.1 Kesimpulan....................................................................................................
6.2 Saran..............................................................................................................
DAFTAR PUSTAKA..........................................................................................
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DAFTAR GAMBAR
Gambar 2.2 Diagram alir dari pembagian perawatan............................................
Gambar 2.3 Ilustrasi Ketersediaan..........................................................................
Gambar 3.1 Flowchart Metodologi Penelitian........................................................
Gambar 4.1 Batu Kapur..........................................................................................
Gambar 4.2Tanah Liat............................................................................................
Gambar 4.3 Pasir Besi............................................................................................
Gambar 4.4 Pasir Silika..........................................................................................
Gambar 4.5 Raw Mill.............................................................................................
Gambar 4.6 Silo Penyimpanan...............................................................................
Gambar 4.7 Proses Pembakaran.............................................................................
Gambar 4.8 Finish Mill...........................................................................................
Gambar 4.9 Proses Packing....................................................................................
Gambar 4.16 Index of Fit........................................................................................
Gambar 4.17 Grafik Fungsi Padat Probabilitas......................................................
Gambar 4.18 Grafik Keandalan Mesin...................................................................
Gambar 4.19 Grafik Laju Kerusakan......................................................................
Gambar 4.20 Laju operasi dan perbaikan...............................................................
Gambar 4.21 Grafik Total Biaya Perawatan...........................................................
Gambar 4.22 Grafik Keandalan Vs Biaya Perawatan.............................................
Gambar 5.1 Fungsi Padat Probabilitas....................................................................
Gambar 5.2 Grafik Keandalan................................................................................
Gambar 5.3 Grafik Laju Kerusakan........................................................................
Gambar 5.4 Laju Operasi dan Perbaikan................................................................
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Gambar 5.5 Grafik Total Biaya Perawatan.............................................................
Gambar 5.6 Grafik Keandalan vs Biaya Perawatan Optimum...............................
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DAFTAR TABEL
Tabel 2.1 Spesifikasi Mesin.....................................................................
Tabel 3.1 Distribusi Chi-Square.............................................................................
Tabel 4.1Data Mesin Kritis dan Tidak Kritis MesinGrinding Mill.....................
Tabel 4.2 Frekuensi Kerusakan..............................................................................
Tabel 4.3 frekuensi penggantian komponenmesin Bucket elevator.....................
Tabel 4.6 Fixed Cost...............................................................................................
Tabel 4.7 Tabel Harga Komponen..........................................................................
Tabel 4.8 Variabel Cost..........................................................................................
Tabel 4.9 Distribusi................................................................................................
Tabel 4.10 Hasil Uji Statistik.................................................................................
Tabel 4.11 Hasil Uji Statistik Lama Mesin menganggur.......................................
Tabel 4.12 Distribusi Weibull................................................................................
Tabel 4.19 Hasil Perbandingan Total Biaya Awal dengan usulan Baru.............
Tabel 4.18 Perbandingan Sebelum dan Sesudah Perbaikan...................................
Tabel 5.1 Hasil Uji Distribusi Waktu Kerusakan...................................................
Tabel 5.2 Hasil Uji Statistik Lama Mesin Menganggur.........................................
Tabel 5.3 Parameter α dan β...................................................................................
Tabel 5.4 Keandalan Mesin Sebelum Perbaikan....................................................
Tabel 5.5 Perbandingan Biaya Perbaikan...............................................................
Tabel 6.1 komponen kritis mesin bucket elevator.................................................
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DAFTAR LAMPIRAN
Lampiran 1.................................................................................................
Lampiran 2.................................................................................................
Lampiran 3.................................................................................................
Lampiran 4.................................................................................................
Lampiran 5.................................................................................................
Lampiran 6.................................................................................................
Lampiran 7.................................................................................................
Lampiran 8.................................................................................................
Lampiran 9.................................................................................................
Lampiran 10...............................................................................................
Lampiran 11...............................................................................................
Lampiran 12...............................................................................................
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