Putri, Regita Destya and Ir. Dwi Hadi Sulistyarini, S.T., M.T. (2024) Perancangan Maintenance Mesin SBO Menggunakan Pendekatan Reliability Centered Maintenance II (Studi Kasus PT Tirta Investama Klaten). Sarjana thesis, Universitas Brawijaya.
Abstract
PT Tirta Investama Klaten merupakan salah satu perusahaan Air Minum Dalam Kemasan yang berada di bawah naungan Danone Group. Selama proses produksi, perusahaan ini menghadapi beberapa kendala salah satunya yaitu belum terpenuhinya target produksi. Kendala ini berakibat pada tingginya angka downtime pada mesin SBO production line 1500 ml sebagai mesin dengan jumlah technical downtime tertinggi dibandingkan dengan mesin lainnya. Selain itu, perusahaan ini masih memprioritaskan tindakan pemeliharaan preventive sebagai business maintenance process-nya dengan total biaya pemeliharaan terbesar yaitu Rp889.823.442 atau 55% dari total keseluruhan. Reliability Centered Maintenance II (RCM II) merupakan strategi pemeliharaan yang diusulkan untuk menangani permasalahan tersebut. Metode ini digunakan untuk menentukan strategi pemeliharaan yang optimal dengan mempertimbangkan efektivitas biaya, tingkat keandalan, keselamatan pekerja, dan kesehatan lingkungan. Langkah yang dilakukan di antaranya identifikasi sistem dan batasan sistem melalui pembuatan Functional Block Diagram, identifikasi system function dan function failure, penyusunan Machine Failure Mode and Effect Analysis (MFMEA) untuk menentukan komponen kritis, identifikasi konsekuensi kegagalan melalui penyusunan logic tree analysis, penyusunan RCM II Information Worksheet, penentuan jenis distribusi dan nilai parameter data Time to Failure (TTF) dan Time to Repair (TTR), perhitungan nilai Mean Time to Failure (MTTF) dan Mean Time to Repair (MTTR), perhitungan interval waktu pemeliharaan optimal, perhitungan total biaya pemeliharaan, perhitungan nilai keandalan, dan penyusunan RCM II Decision Worksheet. Hasil penelitian menunjukan terdapat enam komponen kritis di antaranya komponen loading unloading cam dengan jenis kegagalan silinder macet, preform ejector dengan jenis kegagalan infeed wheel torque, oven unit dengan jenis kegagalan spindle jatuh dan pressure insufficient, cam stretching unit dengan jenis kegagalan stretching rod not in position, mold unit dengan jenis kegagalan mold not locked, komponen starwheel botol dengan jenis kegagalan conveyor wheel torque 2. Berdasarkan RCM II, didapatkan interval waktu pemeliharaan optimal dan tindakan pemeliharaan untuk komponen loading unloading cam yaitu schedule restoration task dengan interval waktu 61,80420073 jam, untuk komponen preform ejector yaitu schedule on condition task dengan interval waktu 180,896421 jam, untuk komponen oven unit yaitu schedule condition task dengan interval waktu 3341,934745 jam dan schedule discard task dengan interval waktu 374,8954023 jam, untuk komponen cam stretching unit yaitu schedule restoration task dengan interval waktu 1632,191982 jam, untuk komponen mold unit yaitu schedule restoration task dengan interval waktu 1690,481107 jam, dan untuk komponen starwheel botol yaitu schedule restoration task dengan interval waktu 403,7244384 jam. Seluruh komponen mesin SBO mengalami penurunan total biaya pemeliharaan setelah diterapkannya interval waktu pemeliharaan optimal dengan nilai keandalan yang turut meningkat kecuali untuk komponen preform ejector dengan jenis kegagalan infeed wheel torque dan komponen oven unit dengan jenis kegagalan spindle jatuh. Kata Kunci : Keandalan
English Abstract
PT Tirta Investama Klaten is a bottled drinking water company under the auspices of the Danone Group. During the production process, this company faced several obstacles, one of which was not meeting production targets. This constraint resulted in a high number of downtimes on the 1500 ml SBO production line machine as the machine with the highest number of technical downtimes compared to other machines. Apart from that, this company still prioritizes preventive maintenance actions as its business maintenance process with the largest total maintenance costs, namely IDR 889,823,442 or 55% of the total. Reliability Centered Maintenance II (RCM II) is a maintenance strategy proposed to address these problems. This method is used to determine optimal maintenance strategies by considering cost effectiveness, level of reliability, worker safety and environmental health. The steps taken include identifying the system and system boundaries through creating a Functional Block Diagram, identifying system functions and function failures, creating a Machine Failure Mode and Effect Analysis (MFMEA) to determine critical components, identifying the consequences of failure through creating a logic tree analysis, creating RCM II Information Worksheet, determining distribution type and Time to Failure (TTF) and Time to Repair (TTR) data parameter values, calculating Mean Time to Failure (MTTF) and Mean Time to Repair (MTTR) values, calculating optimal maintenance time intervals, total calculation maintenance costs, calculation of reliability values, and creating of the RCM II Decision Worksheet. The results of the research show that there are six critical components including the loading unloading cam component with the stuck cylinder failure type, the ejector preform with the infeed wheel torque failure type, the oven unit with the spindle falling and pressure insufficient failure type, the stretching cam unit with the stretching rod not in position failure type. , mold unit with mold not locked failure type, bottle starwheel component with conveyor wheel torque 2 failure type. Based on RCM II, optimal maintenance time intervals and maintenance tasks for the loading unloading cam component are obtained, namely schedule restoration task with a time interval of 61.80420073 hours, for the preform ejector component, namely the schedule on condition task with a time interval of 180.896421 hours, for the oven unit component, namely the schedule condition task with a time interval of 3341.934745 hours and the discard task schedule with a time interval of 374.8954023 hours, for the cam stretching unit component, namely schedule restoration task with a time interval of 1632.191982 hours, for mold unit components, namely a schedule restoration task with a time interval of 1690.481107 hours, and for bottle starwheel components, namely a schedule restoration task with a time interval of 403.7244384 hours. All SBO machine components experienced a decrease in total maintenance costs after implementing the optimal maintenance time interval with reliability values also increasing except for the preform ejector component with the infeed wheel torque failure type and the oven unit component with the falling spindle failure type.
| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 0524070124 |
| Uncontrolled Keywords: | Keandalan Machine Failure Mode and Effect Analysis, Mesin SBO, Pemeliharaan, Reliability Centered Maintenance II-Machine Failure Mode and Effect Analysis, Maintenance, Reliability, Reliability Centered Maintenance II, SBO Machine |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | soegeng sugeng |
| Date Deposited: | 16 May 2024 02:16 |
| Last Modified: | 16 May 2024 02:16 |
| URI: | http://repository.ub.ac.id/id/eprint/218846 |
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