DETAIL KOLEKSI

Usulan manajemen perawatan mesin-mesin pada plant kt 24 pabrik pipa baja berdasarkan metode reliability centered maintenance ii dan reability centered spares di PT. Bakrie Pipe Industries


Oleh : Fariz Fuad Alwainy

Info Katalog

Penerbit : FTI - Usakti

Kota Terbit : Jakarta

Tahun Terbit : 2008

Pembimbing 1 : Ismed Abdurrachman

Subyek : Machinery in industry - Maintenance and repair;Maintainability;Reliability

Kata Kunci : maintenance management, machines, kt 24 plant, pipe factory, steel, reliability centered maintenance

Status Posting : Published

Status : Tidak Lengkap


File Repositori
No. Nama File Hal. Link
1. 2008_TA_STI_06303270_Halaman-Judul.pdf
2. 2008_TA_STI_06303270_Lembar-Pengesahan.pdf
3. 2008_TA_STI_06303270_Bab_1_Pendahuluan.pdf
4. 2008_TA_STI_06303270_Bab_2_Landasan-Teori.pdf
5. 2008_TA_STI_06303270_Bab_3_Metodologi-Penelitian.pdf
6. 2008_TA_STI_06303270_Bab_4_Pengumpulan-Dan-Pengolahan-Data.pdf
7. 2008_TA_STI_06303270_Bab_5_Analisa--Pengolahan-Data.pdf
8. 2008_TA_STI_06303270_Bab_6_Kesimpulan-Dan-Saran.pdf
9. 2008_TA_STI_06303270_Daftar-Pustaka.pdf
10. 2008_TA_STI_06303270_Lampiran.pdf

P PT. Bakrie Pipe Industries adalah perusahaan pembuatan pipa baja dengan kapasitas produksi hingga 303.000 ton per tahunnya. Di PT. Bakrie Pipe Industries lima Plant lantai Produksi yaitu Plant WTM 8, WTM 16, MM 1, VAT 4, dan KT 24. Pada penelitian tugas akhir ini hanya mengamati di plant KT 24. Di plant KT 24 terdapat 22 jenis mesin produksi. Permasalahan yang dihadapi adalah kesulitan dalam mengatur jadwal maintenance serta keberadaan persediaan komponen tidak terkontrol dan segi pendataan dan penyediaannya yang berakibat terhambatnya kegiatan pemeliharaan yang akhirnya akan menghambat jalannya proses produksi. Maka diperlukan perencanaan perawatan mesin yang optimal untuk meminimasi total downtime dan meningkatkan reliabilitas mesin, kemudian diperlukan juga sistem persediaan suku cadang yang optimal. Oleh sebab itu diharapkan dengan penerapan metode Reliability Centered Maintenance II (RCM II) serta Reliability Centered Spares (RCS) permasalahan yang dihadapi oleh perusahaan dapat teratasi. Pada penelitian ini diawali dengan memilih mesin kritis dan unit komponen kritis berdasarkan jumlah mesin didalam lantai produksi. Untuk mendapatkan mesin kritis perhitungan berdasarkan diagram pareto sehingga didapatkan empat mesin kritis yaitu Mesin High Frequency Welder, Electrical Cut Off, Cooling System, dan Mesin Jointing. Kemudian perhitungan dilanjutkan dengan memilih komponen kritis berdasarkan diagram pareto dan didapatkan delapan komponen kritis dari empat mesin kritis. Kemudian dilakukan perencanaan kegiatan dengan pendekatan Reliability Centered Maintenance II (RCM II) yang diawali dengan pembuatan Failure Mode and Effect Critically Analysis (FMECA), Untuk pembuatan FMECA diketahui bahwa komponen Contact Shoe memiliki nilai RPN tertinggi yaitu sebesar 574. Setelah itu membuat RCM II Information Worksheet dan RCM II Decision Worksheet, proposed task yang didapatkan adalah Scheduled On - Condition Task untuk komponen Asw ER Gear wire dan Carriage Motor serta Scheduled Restoration Discard untuk komponen Water Contact Cooling Coil, Limit Switch, Contactor dan juga Scheduled Discard Task untuk komponen Contact Shoe, Measuring Wheel, Fuse. • Perhitungan interval perawatan diawali dengan menghitung selang waktu antar kerusakan dan selang waktu perbaikan. Lalu dilakukan pemilihan distribusi berdasarkan index of fit terbesar dengan menggunakan metode Least Square Curve Fitting (LSCF), kemudian hasil distribusi diuji menggunakan uji-uji khusus dan dilanjutkan dengan penentuan parameter menggunakan metode Maximum Likelihood Estimator (MLE). Perhitungan index of fit dan MLE dilakukan dengan perhitungan manual dan dengan menggunakan software Minitab 13. Setelah itu dihitung interval penggantian berkala dan interval pergantian berkala dengan menggunakan safety factor. Dilanjutkan dengan kebijakan RCS yang diawali dengan pembuatan RCS Worksheet serta RCS Decision Worksheet, Untuk kebijakan RCS diperoleh hasil bahwa komponen Contact Shoe, Water Contact Cooling Coil, Contactor, Asw ER Gear wire sebaiknya distok didalam gudang. Dari perhitungan lot sizing dengan meggunakan metode Period Order Quantity, Economic Order Quantity dan lot for lot didapatkan penggunaan metode Period Order Quantity lebih balk dengan menghasilkan perhitungan biaya yang lebih murah untuk setiap pengadaan material pada tiap-tiap komponen.

P PT. Bakrie Pipe Industries is a steel pipe manufacturing company with a production capacity of up to 303,000 tons per year. At PT. Bakrie Pipe Industries, there are five Production Floor Plants, namely Plant WTM 8, WTM 16, MM 1, VAT 4, and KT 24. In this final project research, only the KT 24 plant was observed. In the KT 24 plant, there are 22 types of production machines. The problems faced are the difficulty in managing maintenance schedules and the existence of uncontrolled component inventory and aspects of data collection and provision which result in delays in maintenance activities which will ultimately hinder the production process. Therefore, optimal machine maintenance planning is needed to minimize total downtime and increase machine reliability, then an optimal spare parts inventory system is also needed. Therefore, it is hoped that by implementing the Reliability Centered Maintenance II (RCM II) and Reliability Centered Spares (RCS) methods, the problems faced by the company can be resolved. This study begins with selecting critical machines and critical component units based on the number of machines in the production floor. To get the critical machine, the calculation is based on the Pareto diagram so that four critical machines are obtained, namely the High Frequency Welder Machine, Electrical Cut Off, Cooling System, and Jointing Machine. Then the calculation is continued by selecting critical components based on the Pareto diagram and eight critical components are obtained from the four critical machines. Then, activity planning is carried out using the Reliability Centered Maintenance II (RCM II) approach which begins with the creation of Failure Mode and Effect Critically Analysis (FMECA). For the creation of FMECA, it is known that the Contact Shoe component has the highest RPN value of 574. After that, the RCM II Information Worksheet and RCM II Decision Worksheet are made, the proposed tasks obtained are Scheduled On - Condition Task for the Asw ER Gear wire and Carriage Motor components and Scheduled Restoration Discard for the Water Contact Cooling Coil, Limit Switch, Contactor components and also Scheduled Discard Task for the Contact Shoe, Measuring Wheel, Fuse components. • Calculation of maintenance intervals begins by calculating the time interval between damage and repair intervals. Then the distribution selection is carried out based on the largest index of fit using the Least Square Curve Fitting (LSCF) method, then the distribution results are tested using special tests and continued with parameter determination using the Maximum Likelihood Estimator (MLE) method. The calculation of the index of fit and MLE is done by manual calculation and using Minitab 13 software. After that, the periodic replacement interval and periodic replacement interval are calculated using the safety factor. Continued with the RCS policy which begins with the creation of the RCS Worksheet and RCS Decision Worksheet. For the RCS policy, the results obtained are that the components of Contact Shoe, Water Contact Cooling Coil, Contactor, Asw ER Gear wire should be stocked in the warehouse. From the calculation of lot sizing using the Period Order Quantity, Economic Order Quantity and lot for lot methods, it is found that the use of the Period Order Quantity method is better by producing cheaper cost calculations for each material procurement for each component.

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