tugas akhir - umm
TRANSCRIPT
TUGAS AKHIR
PENERAPAN TOTAL PRODUCTIVE MAINTENANCE (TPM)
DALAM PENINGKATAN EFEKTIVITAS KINERJA MESIN GILING
(Studi Kasus PT Kebon Agung)
Diajukan Sebagai Salah Satu Syarat Untuk Mendapatkan Gelar Sarjana Teknik Pada
Jurusan Teknik Industri Universitas Muhammdiyah Malang
Disusun Oleh:
Nur Wahidah
201510140311103
FAKULTAS TEKNIK
JURUSAN TEKNIK INDUSTRI
UNIVERSITAS MUHMMADIYAH MALANG
2020
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KATA PENGANTAR
Puji serta syukur penulis panjatkan ke hadirat Allah SWT atas segala limpahan
rahmat dan hidayah-Nya, penyusun tugas akhir yang berjudul “PENERAPAN TOTAL
PRODUCTIVE MAINTENANCE (TPM) DALAM PENINGKATAN EFEKTIVITAS
KINERJA MESIN GILING” dapat diselesaikan dengan baik.
Skripsi ini merupakan tugas akhir yang diajukan untuk memenuhi syarat dalam
memperoleh gelar Sarjana Teknik (ST) pada Fakultas Teknik Universitas Muhammadiyah
Malang.
Beberapa kendala yang penyusun hadapi dalam menyelesaikan skripsi ini,
diantaranya terbatas tenaga, sarana dan prasarana. Akan tetapi dari semua itu dapat diatasi
berkat kerjasama dan bantuan dari bantuan dari berbagai pihak.
Penyusunan skripsi ini dapat selesai dengan baik tidak lepas dari dokumen dan
bantuan berbagai pihak, diantaranya yaitu :
1. Bapak Dr. Fauzan, Mpd selaku Rektor Universitas Muhammadiyah Malang.
2. Bapak Dr. Ahmad Mubin, MT selaku Dekan Fakultas Teknik Universitas
Muhammadiyah Malang.
3. Bapak Prof. Ilyas Masudin, ST.,Mlog.SCM.,PhD Selaku Ketua Jurusan Teknik
Industri Universitas Muhmmadiyah Malang.
4. Bapak Prof. Ilyas Masudin, ST.,Mlog.SCM.,PhD selaku dosen pembimbing I yang
telah meluangkan waktu untuk membimbing dan mengarahkan penulis dalam
menyusun skripsi ini.
5. Bapak Rahmad Wisnu Wardana, SPd., M.Eng selaku dosen pembimbing II yang telah
meluangkan waktu untuk membimbing dan mengarahkan penulis dalam menyusun
skripsi ini sampe selesai.
6. Seluruh Bapak dan Ibu Dosen Jurusan Teknik Industri Universitas Muhammadiyah
Malang yang telah member bekal ilmu pengetahuan sehingga penulis dapat
menyelesaikan studi dan menyelesaikan penulisan tugas akhir ini.
7. Bapak Madra’i dan ibu Betsi selaku orang tua penulis serta seluruh keluarga besar
penulis yang sangat banyak memberikan bantuan moril, material, arahan dan selalu
mendoakan keberhasilan dan keselamatan selama menempuh pendidikan.
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8. Ego Subandira yang banyak meluangkan waktu dan tenaga untuk membimbing dan
memberikan arahan penulis dalam menyelesaikan tugas akhir ini.
9. Rekan-rekan Mahasiswa Teknik Industri yang telah banyak memberikan masukan
kepada penulis baik selama dalam mengikuti perkuliahan maupun dalam penulisan
tugas akhir ini.
10. Kepada semua pihak yang tidak dapat penulis sebutkan satu persatu yang telah banyak
membantu selama pengerjaan tugas akhir ini.
Akhirnya, dengan segala kerendahan hati penulis menyadari masih banyak terdapat
kekurangan-kekurangan, sehingga penulis mengharapkan adanya saran dan kritik yang
bersifat membangun demi kesempurnaan tugas akhir ini.
28 Oktober 2020
Penulis
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DAFTAR ISI
BERITA ACARA UJIAN.................................................................................................
SURAT PERNYATAAN KEASLIAN............................................................................
SURAT KETERANGAN DARI PERUSAHAAN.........................................................
KATA PENGANTAR ........................................................................................................ i
ABSTRAK ........................................................................................................................ iii
ABSTRACT ....................................................................................................................... iv
DAFTAR ISI ...................................................................................................................... v
DAFTAR TABEL ............................................................................................................ ix
DAFTAR GAMBAR ......................................................................................................... x
DAFTAR LAMPIRAN .................................................................................................... xi
BAB I .................................................................................................................................. 1
PENDAHULUAN .............................................................................................................. 1
1.1. Latar Belakang ............................................................................................... 1
1.2. Rumusan Masalah .......................................................................................... 2
1.3. Tujuan Peneltian ............................................................................................ 2
1.4. Manfaat Penulisan .......................................................................................... 3
1.5. Batasan Masalah dan Asumsi ........................................................................ 3
BAB II ................................................................................................................................ 4
LANDASAN TEORI ......................................................................................................... 4
2.1. Perawatan (Maintenance) .............................................................................. 4
2.1.1. Tujuan Maintenance ..................................................................................... 4
2.1.2. Jenis –jenis Maintenance............................................................................... 5
2.2. Total Productive Maintenance (TPM) ........................................................... 7
2.2.1. Pengertian Total Productive Maintenance (TPM) ........................................ 7
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2.2.2. Tujuan Total Productive Maintenance (TPM) .............................................. 8
2.2.3. Target Total Productive Maintenance (TPM) ................................................ 9
2.2.4. Pilar-pilar Total productive Maintenance (TPM) ....................................... 10
2.3. Overall Equipment Effectiveness (OEE) ..................................................... 13
2.3.1. Definisi Overall Equipment Effectiveness (OEE) ...................................... 13
2.3.2. Tujuan Implementasi OEE (Overal Equipment Effectiveness) .................. 14
2.3.3. Perhitungan Nilai OEE Overal Equipment Effectiveness) ......................... 15
2.4. Alat pemecah masalah ................................................................................. 18
BAB III ............................................................................................................................. 22
METOLOGI PENELITIAN .......................................................................................... 22
3.1. Metologi Penelitian ...................................................................................... 22
3.2. Flowchat Penelitian ..................................................................................... 22
3.3. Penjelasan Flowchart Penelitian .................................................................. 23
BAB IV ............................................................................................................................. 30
PENGUMPULAN DAN PENGOLAHAN DATA........................................................ 30
4.1. Tinjauan Perusahaan .................................................................................... 30
4.1.1. Sejarah Perusahaan...................................................................................... 30
4.1.2. Visi Misi PT Kebon Agung ........................................................................ 31
4.1.3. Struktur Organisasi PT Kebon Agung ........................................................ 32
4.1.4. Proses Produksi ........................................................................................... 35
4.2. Pengumpulan Data ....................................................................................... 45
4.2.1. Data Jumlah Produksi ................................................................................. 45
4.2.2. Data Produk Cacat....................................................................................... 45
4.2.3. Data Available Time ................................................................................... 46
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4.2.4. Data Downtime ........................................................................................... 47
4.2.5. Data Planned Downtime ............................................................................. 47
4.3. Pengolahan Data .......................................................................................... 48
4.3.1. Persediaan (Availability Rate) .................................................................... 48
4.3.2. Efektivitas Kinerja (Performance Rate) ...................................................... 50
4.3.3. Tingkat Kualitas Produk (Quality Rate) ..................................................... 54
4.3.4. Overall Equipment Effectiveness (OEE) .................................................... 55
4.4. Six Big Losses ............................................................................................. 55
4.4.1. Equipment Failure Losses ........................................................................... 56
4.4.2. Set up and adjustment losses ....................................................................... 57
4.4.3. Idling and minor stoppage losses ................................................................ 58
4.4.4. Reduced speed losses .................................................................................. 59
4.4.5. Quality Defect and Rework ......................................................................... 60
4.5. Diagram pareto ............................................................................................ 61
BAB V ............................................................................................................................... 62
ANALISA PEMBAHASAN ........................................................................................... 62
5.1. Analisa Persediaan (Availability Rate) ........................................................ 62
5.2. Analisa Efektifitas Kinerja (Performance Rate) .......................................... 63
5.3. Analisa Tingkat Kualitas Produk (Quality Rate) ......................................... 64
5.4. Analisa Overall Equipment Effectiveness (OEE) ........................................ 65
5.5. Analisa Six Big Losses ................................................................................ 66
5.6. Analisa diagram fishbone ............................................................................. 68
5.6.1. Analisa quality defect and rework............................................................... 68
5.6.2. Analisa Reduced Speed losses ..................................................................... 71
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5.7. Penerapan Total Productive Maintenance (TPM) ....................................... 74
BAB VI ............................................................................................................................. 77
KESIMPULAN DAN SARAN ....................................................................................... 77
6.1. Kesimpulan .................................................................................................. 77
6.2. Saran ............................................................................................................ 78
Daftar Pustaka ................................................................................................................. 80
LAMPIRAN ..................................................................................................................... 82
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DAFTAR TABEL
Tabel 3 1 Contoh tabel pengambilan data ......................................................................... 30
Tabel 4 1 Data Jumlah produksi ....................................................................................... 55
Tabel 4 2 Data produk cacat ............................................................................................. 55
Tabel 4 3 Data available Time PT Kebon Agung ............................................................. 56
Tabel 4 4 Data Downtime PT Kebon Agung .................................................................... 57
Tabel 4 5 Data Planned Downtime di PT Kebon Agung .................................................. 57
Tabel 4 6 Hasil perhitungan Loading time ........................................................................ 58
Tabel 4 7 Hasil perhitungan Operation time ..................................................................... 59
Tabel 4 8 Hasil perhitungan Availability rate ................................................................... 60
Tabel 4 9 Hasil perhitungan waktu siklus produksi .......................................................... 61
Tabel 4 10 Hasil perhitungan presentasi waktu kerja ....................................................... 62
Tabel 4 11 Hasil perhitungan Ideal cycle time.................................................................. 63
Tabel 4 12 Hasil perhitungan Performance Rate .............................................................. 63
Tabel 4 13 Hasil perhitungan Quality Rate ....................................................................... 64
Tabel 4 14 Hasil perhitungan nilai OEE ........................................................................... 65
Tabel 4 15 Hasil perhitungan equipment failure losses .................................................... 66
Tabel 4 16 Hasil perhitungan set up and adjustment losses .............................................. 67
Tabel 4 17 Hasil perhitungan Idling and minor stoppage losses ...................................... 68
Tabel 4 18 Hasil perhitungan Reduced speed losses ........................................................ 70
Tabel 4 19 Hasil perhitungan Quality defect & rework .................................................... 71
Tabel 4 20 Kumulatif total time losses ............................................................................. 71
Tabel 5 1 Perhitungan six big losses ................................................................................. 78
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DAFTAR GAMBAR
Gambar 2 1. 8 pilar TPM .................................................................................................. 17
Gambar 2 2 Contoh Gambar diagram pareto .................................................................... 25
Gambar 2 3 Contoh gambar diagram Fishbone ................................................................ 27
Gambar 3 1 Flowchart Penelitian ...................................................................................... 29
Gambar 4 1 Struktur Organisasi PT Kebon Agung .......................................................... 39
Gambar 4 2 Diagram aliran proses produksi gula ............................................................. 44
Gambar 4 3 Aliran proses penggilingan............................................................................ 47
Gambar 4 4 Diagram alir proses pemurnian ..................................................................... 49
Gambar 4 5 Diagram alir proses penguapan ..................................................................... 52
Gambar 4 6 Diagram alir proses masakan ........................................................................ 53
Gambar 4 7 Diagram alir proses puteran .......................................................................... 54
Gambar 4 8 Diagram alir proses pengeringan................................................................... 55
Gambar 5 1 Grafik hasil Perhitungan availability............................................................. 74
Gambar 5 2 Grafik hasil Perhitungan Performance rate ................................................... 75
Gambar 5 3 Grafik hasil Perhitungan Quality rate............................................................ 76
Gambar 5 4 Grafik hasil Perhitungan Overall Equipment Effectiveness (OEE) .............. 77
Gambar 5 5 Diagram pareto six big losses ....................................................................... 79
Gambar 5 6 Diagram fishbone quality defect and rework ................................................ 80
Gambar 5 7 Diagram fishbone Reduced Speed losses ..................................................... 82
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