Usulan perawatan encegahan berdasarkan kriteria minimasi downtime komponen kritis di PT. Yamaha Indonesia Motor Manufakturing
Info Katalog
File Repositori
Penerbit : FTI - Usakti
Kota Terbit : Jakarta
Tahun Terbit : 2002
Pembimbing 1 : Pudji Astuti
Subyek : Total productive maintenance;Production management
Kata Kunci : preventive maintenance, total downtime machine
Status Posting : Published
Status : Lengkap
File Repositori
| No. | Nama File | Hal. | Link |
|---|---|---|---|
| 1. | 2002_TA_STI_06397244_Halaman-Judul.pdf | ||
| 2. | 2002_TA_STI_06397244_Lembar-Pengesahan.pdf | ||
| 3. | 2002_TA_STI_06397244_Bab-1_Pendahuluan.pdf | ||
| 4. | 2002_TA_STI_06397244_Bab-2_Landasn-Teori.pdf |
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| 5. | 2002_TA_STI_06397244_Bab-3_Metodologi-Penelitian.pdf |
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| 6. | 2002_TA_STI_06397244_Bab-4_Pengumpulan-dan-Pengolahan-Data.pdf |
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| 7. | 2002_TA_STI_06397244_Bab-5_Analisa-Hasil.pdf |
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| 8. | 2002_TA_STI_06397244_Bab-6_Kesimpulan-dan-Saran.pdf | ||
| 9. | 2002_TA_STI_06397244_Daftar-Pustaka.pdf | ||
| 10. | 2002_TA_STI_06397244_Lampiran.pdf |
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P PT YAMAHA MOTOR INDONESIA MANUFAKTURING adalah perusahaan manufaktur yang memproduksi dan merakit motorcycle dan komponen-komponennya, Air tools, Water Purifier & alat-alat musik. Kerusakan mesin dan peralatan produksi sering terjadi. dimana perbaikannya memerlukan waktu yang dapat mengganggu proses produksi yang telah dijadwalkan, Mesin-mesin produksi di seluruh departemen PT YAMAHA INDONESIA MOTOR MANUFAKTURING sebagian besar memproduksi motorcycle. Sehingga ada kecenderungan bahwa perubahan sistem corrective maintenance menjadi preventive maintenance yang diinginkan perusahaan untuk mengurangi waktu produksi yang terhenti karena kerusakan mendadak akan memberi dampak lebih besar pada mesin-mesin produksi motorcycle. Oleh karena itu perlu dilakukan evaluasi terhadap sistem perawatan yang ada, dengan terlebih dahulu mengetahui umur penggantian komponen. Dari penelitian pendahuluan diketahui bahwa total kerusakan mesin terbesar ada di Maintenance 2, departemen 5 dan shop Die Casting line 2 yang memproduksi Body Cylinder & Crank Case. Berdasarkan data-data kerusakan yang diperoleh dari Shop Die casting line 2 dari bulan Juni 2000 sampai dengan Juli 2001, diketahui bahwa mesin-mesin yang dikategorikan mesin kritis berdasarkan diagram Pareto adalah mesin DC UBE NX $800, mesin Tost Cast Toshiba $800, mesin DC $650-2 & mesin DC $650-2. Kemudian ditentukan komponen kritis dari keempat mesin tersebut dengan menggunakan diagram pareto. Komponen kritis untuk mesin DC UBE NX $800 adalah Hidrolic House, Extractor Wire & Rod Ejector. Komponen kritis untuk mesin Tost Cast Toshiba $800 adalah Baut Hand ExtractorM8, Rod Ejector, Bearing, Speed Control Cylinder & Hand Extractor. Lalu komponen kritis untuk mesin DC $650-2 adalah Cylinder Pipe, Cartridge Pump, Male Fitting, Fitting Spray & Hidrolic House. Dan komponen kritis untuk mesin DC $650-1 adalah Solenoid Valve, Hidrolic Pipe, Rod Ejector, Extractor Wire & Extractor Pipe. Perhitungan interval waktu penggantian pencegahan, interval pemeriksaan, downtime pemeriksaan & Tingkat Ketersediaan menggunakan kriteria minimasi downtime. Umur penggantian optimalnya untuk mesin DC UBE NX $800: Hydrolic House = 900 jam, Extractor Wire = 800 jam & Rod Ejector = 1600 jam, TOSCAST $800 : Baut Hand Extractor = 1200 jam, Bearing = 2650 jam, Speed Control Cycle = 1700 jam, Hand Extractor = 2100 jam & Rod Ejector = 1050 jam, DC $ 650-2 : Cylinder Pipe = 1900 jam, Cartridge Pump = 2100 jam, Male Fitting = 1200 jam, Fitting Spray = 2350 jam & Hydrolic House = 1900 jam, DC $650-1 are Solenoid Valve = 1200 jam, Rod Ejector = 1850 jam, Extractor Wire = 1700 jam, Hydrolic Pipe = 3750 jam and Extractor Pipe = 4600 jam. Dengan dilakukannya tindakan perawatan pencegahan, maka terjadi peningkatan keandalan yang cukup significan saat sebelum preventive maintenance dan sesudah preventive maintenance
P PT YAMAHA MOTOR INDONESIA MANUFAKTURING is a manufacturing company which is producing and assembling motorcycles and its parts, air tools, water purifiers and music instruments. PT YAMAHA MOTOR INDONESIA MANUFAKTURING always trying to give the best quality & services The delayed production process that caused by the breakdown of production machines and equipment spend much times. It takes time and disturbs the production process according to the schedule. Most production machines in all of the departments of PT YAMAHA INDONESIA MOTOR MANUFAKTURING produce motorcycles. So there is an inclination that any change of the corrective maintenance into preventive maintenance desired by the company to reduce the sudden delayed production, will take a great impact to the motorcycles production machines. Therefore, it is necessary to evaluate the existing maintenance method, by observe the component replacement age first. From the preliminary research, it is concluded that the total downtime machines taking place in maintenance division 2, department 5 and shop die casting line 2 that produce body cylinder and crank case. Based on the data of downtime machines that took from the shop die casting line 2 in June 2000 to July 2001, it is revealed that the categorized of critical machines based on pareto diagram are DC UBE NX $800, TOSCAST Toshiba $800, DC $650-2 & DC $650-1. Then the critical components of the four machines above using pareto diagram are : DC UBE NX $ 800 are Hydrolic House, Extractor Wire & Rod Ejector, TOSCAST Toshiba $800 are Bolt Hand Extractor, Bearing, Speed Control Cycle, Hand Extractor & Rod Ejector, DC $650-2 are Cylinder Pipe, Cartridge Pump, Male Fitting, Fitting Spray & Hydrolic House and DC machine $650-1 are Solenoid Valve, Hydrolic Pipe , Extractor Wire, Rod Ejector & Extractor Pipe. The calculates of the preventive replacement, interval inspection, availability and relliability are based on minimized downtime criteria. The preventive replacement for DC UBE NX $800 are Hydrolic House = 900 hours, Extractor Wire = 800 hours & Rod Ejector = 1600 hours, TOSCAST $800 are Bolt Hand Extractor = 1200 hours, Bearing = 2650 hours, Speed Control Cycle = 1700 hours, Hand Extractor = 2100 hours & Rod Ejector = 1050 hours, DC $ 650-2 are Cylinder Pipe = 1900 hours, Cartridge Pump = 2100 hours, Male Fitting = 1200 hours, Fitting Spray = 2350 hours & Hydrolic House = 1900 hours, DC $650-1 are Solenoid Valve = 1200 hours, Rod Ejector = 1850 hours, Extractor Wire = 1700 hours, Hydrolic Pipe = 3750 hours and Extractor Pipe = 4600 hours.The preventive maintenance caused the increase of reliability improvement that significant enough to compare both of recent condition (without the preventive maintenance) and proposed condition (with preventive maintenance).
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