Lukodono, RioPrasetyo (2013) Analisis Penerapan Metode Reliability Centered Maintenance (RCM) dan Maintenance Value Stream Mapping (MVSM) untuk Meningkatkan Keandalan pada Sistem Maintenance (Studi Kasus Pabrik Gula X). Magister thesis, Universitas Brawijaya.
Abstract
Penelitian ini dilakukan untuk memberikan pendekatan baru terhadap sistem perawatan mesin pada PG. X. Pada PG. X telah menerapkan 3 macam pola perawatan antara lain: overhaul, corrective maintenance, dan mill wash . Walaupun telah melakukan 3 macam program perawatan mesin tetapi downtime yang terjadi masih tinggi. Tercatat pada tahun 2012 jumlah downtime yaitu sebesar 241,83 Jam. Hal ini menunjukkan adanya masalah dengan sistem perawatan sekarang dimana waktu downtime ideal yang dimiliki oleh sebuah mesin sebaiknya dibuat seminimal mungkin. Downtime yang tinggi berdampak buruk untuk perusahaan terkait kerugian potensi keuntungan, biaya tenaga kerja, dan tertundanya jadwal produksi perusahaan. Berdasarakan analisis pendahuluan tingginya downtime tersebut diakibatkan oleh tiga hal antara lain: belum adanya bagian yang menangangi perawaatan secara khusus, belum adanya analisis keandalan pada mesin, dan belum terprogramnya SOP saat melakukan aktivitas perawatan aktual. Penelitian ini memberikan usulan penggabungan metode RCM dan MVSM untuk mengatasi hal tersebut. Pada metode RCM dilakukan proses melalui pemilihan sistem dan pengumpulan informasi, pendefinisian batasan sistem, pembuatan diagram blok fungsional, pembuatan FMEA, analisis keandalan, dan pembuatan RCM Decision Worksheet . Sedangkan pada MVSM dilakukan proses pengolahan sebagai berikut: analisis aktivitas aktual, penggambaran current state value stream map, analisis waste , pembuatan usulan perbaikan, dan penggambaran future state value stream map . Hasil penelitian menunjukkan bahwa downtime tertinggi terjadi pada Stasiun Gilingan dengan mesin kritisnya Cane Carrier I, Cane Carrier II, dan Unigrator. Dari pengolahan data dan perhitungan RCM, didapatkan jenis perawatan berupa: Rantai Cane Carrier I dengan tipe perawatan Scheduled On Condition Task dan interval perawatan 3642,23 Jam, Sprocket Cane Carrier I dengan tipe perawatan Combination Task dan interval perawatan 974,71 Jam, Slat Cane Carrier I dengan tipe perawatan Schedule On Condition Task dan interval perawatan 974,71 Jam, Rantai Cane Carrier II dengan tipe perawatan Schedule On Condition Task dan interval perawatan 5.588,68 Jam, Sprocket Cane Carrier II dengan tipe perawatan Combination Task dan interval perawatan 905,614 Jam, Rotor Unigrator dengan tipe perawatan Combination Task dan interval perawatan 1.103,79 Jam, Stang Hammer Unigrator dengan tipe perawatan Combination Task dan interval perawatan 2.638,76 Jam. Hasil pengolahan MVSM didapatkan usulan perbaikan berupa pembuatan SOP dan 5R. Pembuatan SOP ini juga menggunakan dasar tipe perawatan dan interval perawatan dari hasil RCM. Sehingga terjadi pengurangan waktu delay yang meningkatkan Maintenance Efficiency aktivitas perawatan aktual sebesar 7 % sampai 21 %.
English Abstract
This research was conducted to provide a new approach to maintenance system on machine of PG. X. PG. X has implemented three kinds of patterns of maintenance include: overhaul, corrective maintenance, and mill wash. Although it has made 3 kinds of maintenance program but downtime occurs still high. Recorded in 2012 amount of downtime that is equal to 241.83 hours. This indicates a problem with current maintenance system because ideal downtime is owned by a machine should be kept to a minimum. High downtime is bad for companys losses related to potential benefits, labor costs, and delays in companys production schedule. Based on preliminary analysis of high downtime is caused by three things, among o rs: department that handles of maintenance, lack of analysis of reliability of machine, and not standarized of maintenance procedure. This study proposes merge RCM and MVSM methods to overcome it. In RCM method performed through by: selection process and information ga ring systems, defining system boundaries, functional block diagram creation, FMEA process, reliability analysis, and process of RCM Decision Worksheet. While on MVSM done processing as follows: analysis of actual activity, drawing current state value stream map, analysis of waste, making proposed improvements, and depiction of future state value stream map. results showed that highest downtime at Mill Station with critical engine Cane Carrier I, Cane Carrier II, and Unigrator. Data processing and calculation of RCM, got kind of treatment include: type of maintenance II Cane Carrier I is Scheduled On Condition Task and maintenance intervals 3642.23 hours, type of maintenance Sprocket Cane Carrier I is Combination Task and maintenance interval 974.71 Hour, type of maintenance Slat Cane Carrier I is Scheduled On Condition Task and maintenance intervals 974.71 Hours, type of maintenance Chain Cane Carrier II is Schedule On Condition Task and maintenance interval 5588.68 Hours, type maintenance of Sprocket Cane Carrier II is Combination task and maintenance interval 905.614 Hours, type maintenance of Rotor Unigrator is Combination task and maintenance interval 1.103.79 hours, type of maintenance Stang Hammer Unigrator is Combination Task and maintenance intervals 2.638,76 Hours. results obtained MVSM processing improvements proposed SOP form and 5S. Making SOP also uses type of maintenance and maintenance intervals from RCM. Resulting in a reduction in time delay that increases Maintenance Efficiency actual activity by 7% to 21%.
| Item Type: | Thesis (Magister) |
|---|---|
| Identification Number: | TES/664.1/LUK/a/041300765 |
| Subjects: | 600 Technology (Applied sciences) > 664 Food technology > 664.1 Sugar, syrup, their derived products |
| Divisions: | S2/S3 > Magister Teknik Elektro, Fakultas Teknik |
| Depositing User: | Endro Setyobudi |
| Date Deposited: | 17 Oct 2013 15:33 |
| Last Modified: | 17 Oct 2013 15:33 |
| URI: | http://repository.ub.ac.id/id/eprint/160130 |
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