Aulia, Iqlima Tristy (2018) Analisis Risiko Kegagalan Mesin Produksi Spunpile dengan Metode FMEA dan FTA pada PT. Adhi Persada Beton. Sarjana thesis, Universitas Brawijaya.
Abstract
PT. Adhi Persada Beton adalah perusahaan manufaktur yang bergerak di bidang pencetakan beton pada suatu proyek. Produk yang dijadikan objek pada penelitian ini yaitu produk spunpile, karena produk spunpile merupakan produk yang sering dipesan. Dalam proses produksinya, PT. Adhi Persada Beton mempunyai permasalahan yang berkaitan dalam proses produksi yaitu keterlambatan proses produksi beton spunpile. Produksi beton spunpile yang selalu kurang dari rencana produksi menyebabkan terlambatnya pula pengiriman beton ke pelanggan. Melalui hasil wawancara dan diskusi dengan pihak supervisor equipment, keterlambatan produksi beton pada PT. Adhi Persada Beton disebabkan karena faktor mesin produksi yang sering mengalami downtime. Oleh karena itu, PT. Adhi Persada Beton membutuhkan penyelesaian permasalahan downtime yang terjadi yaitu dengan menganalisis risiko kegagalan yang terjadi. Pada penelitian ini dilakukan pengumpulan data berupa kegagalan-kegagalan mesin yang terjadi pada mesin Steaming, Overhead Gantry 1, Overhead Gantry 2, Portal Gantry 1, dan Portal Gantry 2. Lalu dilakukan analisis dengan menggunakan metode FMEA dan didapatkan nilai RPN tertinggi dari tiap mesin. Setelah itu, dilanjutkan dengan menggunakan metode FTA secara kuantitatif untuk mencari basic event dari kegagalan kritis pada mesin-mesin produksi dan menghitung probabilitas kegagalan yang terjadi. Selanjutnya dilakukan analisis dan pembahasan serta pemberian rekomendasi perbaikan untuk mengurangi risiko kegagalan mesin. Penelitian menunjukkan bahwa berdasarkan analisis, didapatkan kegagalan kritis pada mesin Steaming karena bearing yang rusak dan cover pillow block yang lepas dan terdapat 2 basic event yaitu karena blower tidak balance dan terdapat misalignment pada motor dan blower. Pada mesin Overhead Gantry 1 kegagalan kritis karena remote rusak yang disebabkan oleh kejadian tombol yang tidak berfungsi, komponen yang patah dan kabel terputus dan terdapat 3 basic event yaitu karena penyimpanan remote yang tidak tepat, cara pengoperasian remote yang kurang tepat dan tertindih operator saat mengoperasikan remote. Pada mesin Overhead Gantry 2 kegagalan kritis karena gear box bermasalah dan terdapat 2 basic event yaitu karena pengecekan roda gigi saat pelumasan kurang diperhatikan dan dan interval pemberian oli kurang diperhatikan dengan yang dianjurkan. Pada mesin Portal Gantry 1 kegagalan kritis karena reswitch yang disebabkan oleh reswitch yang terjadi karena carbon brush habis dan karena lengan stick reswitch yang patah, terdapat 2 basic event peyebab terjadinya reswitch yaitu karena carbon brush habis dan pengoperasian stick reswitch kurang tepat. Pada mesin Portal Gantry 2 kegagalan kritis karena reswitch dan terdapat 1 basic event peyebab terjadinya reswitch yaitu karena carbon brush habis. Usulan perbaikan yang dapat diberikan berupa pemberian pelumas secara berkala, pembuatan checksheet harian, penggantian oli setiap 1500 jam, dan penggantian carbon brush sesuai dengan jadwal yang disarankan berdasarkan perhitungan MTBF dan MTTR yang telah disesuaikan dengan data kegagalan perusahaan.
English Abstract
PT. Adhi Persada Beton manufacturing company is a project-based producer for making concrete. Researchers choose spunpile concrete because spunpile is the most requested concrete to produce. In the production process, PT. Adhi Persada Beton had problems related to the delay of spunpile production processes. Spunpile production number is lower than the production plan resulting the concrete delivery delayed to the customer. Through interviews and discussions with the supervisor of the concrete production equipment, delay in PT. Adhi Persada Beton due to several factors of production machines that are often experienced downtime. Therefore, PT. Adhi Persada Beton requires problem solution by analyzing the risk of failure happened. In this study, data were collected from engine failures that occured on a Steaming machine, Overhead Gantry 1, Overhead Gantry 2, Portal Gantry 1, Gantry and Portal 2. FMEA is used to analyze the highest RPN value from each machine. After that, followed by the quantitative FTA method to find basic event of a critical failure and given the probability of failures on these machines. Next, the result is analyzed and discussed to make some recommendations for managing risk of failures. Research shows that based on the analysis, the critical engine failures on Steaming machines is because of the damaged of the bearing and cover pillow block that turned off. There are 2 basic events, because the blower was not balance and there was a misalignment in the motor and blower. On Overhead Gantry 1 critical failure is found, it is because of the damaged remote which are the remote button is not working, broken components and cables are disconnected. There are 3 basic events because remote storage wasn’t put off appropriately, the operation of remote was less precise and the cable was trampled by operators when operating the remote. On Overhead Gantry 2 critical failures are found because of the problematic gear box. There are 2 basic events, because checking gears when the lubrication was less noted and the interval for granting of oil were exceeded from the recommendation of the manual book. On Portal Gantry 1 critical failure is found because of reswitch, the reswitch is caused by the carbon brush out of stock and because of a broken arm reswitch stick. There are two basic events, because of the carbon brush was out of stock and the operation of the stick reswitch was less precise. On Portal Gantry 2 critical failures is found because of reswitch and there is 1 basic event because the carbon brush is out of stock. The policy recommendation that can be given in the form of periodic checking to reduce vibration, making the remote container, SOP and daily checksheet, replace of fuel oil every year, and replace the carbon brush according to the recommended schedule based on the calculation of MTBF and MTTR which has adapted from the data company's failure.
Other obstract
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| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | SKR/FT/2018/1132/051812125 |
| Uncontrolled Keywords: | Downtime Mesin, Failure Mode Effect Analysis, Fault Tree Analysis¸ Mean Time Between Failure, Mean Time To Repair |
| Subjects: | 600 Technology (Applied sciences) > 658 General management > 658.2 Plant management > 658.202 Maintenance management |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Budi Wahyono Wahyono |
| Date Deposited: | 11 May 2020 04:40 |
| Last Modified: | 28 Oct 2021 03:19 |
| URI: | http://repository.ub.ac.id/id/eprint/167201 |
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