Implementasi Dari Metode Lean Six Sigma Untuk Saving Energy di Pabrik Gula Gempolkrep Pt Perkebunan Nusantara X

Rachmadi, Raji (2023) Implementasi Dari Metode Lean Six Sigma Untuk Saving Energy di Pabrik Gula Gempolkrep Pt Perkebunan Nusantara X. Masters thesis, Institur Teknoloagi Sepuluh Nopember.

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Abstract

Pabrik Gula Gempolkrep merupakan salah satu pabrik gula terbesar yang dimiliki oleh PT. Perkebunan Nusantara X yang berada di wilayah Mojokerto –Jawa Timur. Salah satu cara agar PG Gempolkep tetap kompetetif adalah dengan beroperasi secara efisien atau meningkatkan operational excellence salah satu nya dengan meminimalkan penggunaan energi. Tujuan implementasi operational excellence di sisi energi adalah untuk meminimalkan biaya, untuk menghilangkan proses produksi yang mengganggu, untuk mengurangi transaksi dan biaya, dan untuk mengoptimalkan proses bisnis. Selama dua decade terakhir, Lean Six Sigma telah berkembang dari teknik pemecahan masalah secara statistik menjadi strategi manajemen dan akhirnya menjadi filosofi perbaikan berkelanjutan. Bagi Manajemen PT Perkebunan Nusantara X, operational excellence berarti secara efisien memberikan produk dan layanan yang dapat diandalkan dengan harga bersaing dan mudah untuk didapatkan. Oleh karena itu, untuk mengatasi masalah tersebut diperlukan pendekatan konsep Lean six sigma. Berdasarkan siklus define, measure, analyze, improve dan control (DMAIC) dengan bantuan alat analisis berupa Diagram Pareto, Root Cause Analysis (RCA) yang berupa diagram Fishbone dalam upaya mengetahui faktor-faktor penyebab konsumsi energi di Pabrik Gula Gempolkrep setelah itu dilakukan wawancara dan pengamatan langsung dengan metode lean menggunakan value stream mapping untuk mengidentifikasi terdapatnya waste atau pemborosan energi pada saat proses produksi kemudian dilakukan penyusunan strategi maupun rekomendasi perbaikan serta pengamatan dilapangan berdasarkan target yang diharapkan. Berdasarkan hasil penelitian saving energy di Pabrik Gula Gempolkrep dipengaruhi oleh produksi uap baru, produksi tebu digiling, utilitas pabrik dan penggunaan listrik di Turbin Altenator sehingga strategi yang dilakukan yaitu dengan :
1. Meningkatkan Rasio listrik TA/Ton tebu giling dengan
a. Elektrifikasi penggerak Cane Cutter 2 -> Disamping meningkatkan ratio listrik TA/ton tebu giling juga dapat meningkatkan ektraksi pemerahan di St. Gilingan
2. Menurunkan rasio steam flow/ton tebu dengan cara menekan konsumsi exhaust steam sebagai berikut:
a. Bleeding Uap Nira 1 melayani 8 Vacuum Pan -> Untuk melakukan optimalisasi distribusi uap proses pembuatan gula
b. Bleeding Uap Nira 2 melayani 3 Vacuum pan, Juice Heater 1 dan Firststage Juice heater 2 -> Untuk melakukan ptimalisasi distribusi uap proses pembuatan gula
c. Exhaust Steam melayani Badan Penguapan No 1 dan Last stage JuiceHeater
3. Meningkatkan rasio steam flow/ton ampas dengan cara meningkatkan efisiensi
Boiler sebagai berikut:
a. Operasional pompa kondensat langsung menuju daerator -> Meningkatkan suhu Air pengisi boiler yang semula tercapai 90C menjadi 105 C
b. Menutup 3 unit valve blow up LPSH -> Menurunkan losses Uap di proses
c. Perbaikan ducting udara pembakaran dan jalur gas asap boiler yoshimine 2 -> Meningkatkan temperature udara pembangkaran boiler
Dengan merealisasikan program efisiensi energi akan mendapatkan manfaat:
a. Pada Kapasitas Giling 6.800 TCD yang semula surplus ampas senilai 12 M menjadi surplus 18,1 M sehingga total nilai penghematan sebesar 6,1 M
per musim giling dan nilai DPMO ke Sigma Value semula 3,45 menjadi 3,51
b. Pada Kapasitas Giling 6.000 TCD yang semula surplus ampas senilai 1,6 M menjadi surplus 7 M sehingga total nilai penghematan sebesar 5,4 M per musim giling dan nilai DPMO ke Sigma Value semula 3,31 menjadi 3,35
c. Pada Kapasitas Giling 5.500 TCD yang semula membutuhkan biaya ampas senilai 4,1 M menjadi surplus ampas senilai 587 juta sehingga total nilai penghematan sebesar 4,7 M per musim giling dan nilai DPMO ke Sigma Value semula 3,23 menjadi 3,26
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Gempolkrep Sugar Factory is one of the largest sugar factories owned by PT. Nusantara X Plantation is located in the Mojokerto area – East Java. One way to keep PG Gempolkep competitive is to operate efficiently or improve operational excellence, one of which is by minimizing energy use. The objective of implementing operational excellence on the energy side is to minimize costs, to eliminate disruptive production processes, to reduce transactions and costs, and to optimize business processes. Over the last two decades, Lean Six Sigma has evolved from a statistical problem solving technique to a management strategy and finally to a philosophy of continuous improvement. For the Management of PT Perkebunan Nusantara X, operational excellence means efficiently providing reliable products and services at competitive prices and easy to obtain. Therefore, to overcome this problem, a lean six sigma concept approach is needed. Based on the define, measure, analyze, improve and control (DMAIC) cycle with the help of analysis tools in the form of Pareto Diagrams, Root Cause Analysis (RCA) in the form of Fishbone diagrams in an effort to find out the factors that cause energy consumption at the Gempolkrep Sugar Factory after that interviews and direct observation with the lean method using value stream mapping to identify the presence of waste or wastage of energy during the production process, then strategies and recommendations for improvement are carried out as well as observations in the field based on the expected target. Based on the research results, saving energy at the Gempolkreo Sugar Factory is influenced by new steam production, milled sugarcane production, factory utilities and electricity usage in the Altenator Turbine, so the strategy undertaken is to: 1. Increasing the ratio of electricity TA/Ton of milled sugarcane with a. Electrification of Cane Cutter 2 drives -> Besides increasing the electricity ratio TA/ton of milled sugar cane, it can also increase milk extraction in St. Mill 2. Reducing the ratio of steam flow/ton of sugar cane by reducing the consumption of exhaust steam as follows: a. Vapor Steam Bleeding 1 serves 8 Vacuum Pans -> To optimize the distribution of steam in the process of making sugar b. Nira 2 Steam Bleeding serves 3 Vacuum pans, Juice Heater 1 and First stage Juice heater 2 -> To optimize the distribution of steam in the process of making sugar c. Exhaust Steam serves the No. 1 Evaporation Agency and Last stage Juice Heater 3. Increase the ratio of steam flow/ton of drag by increasing boiler efficiency as follows: a. Operation of the condensate pump goes directly to the daerator -> Increases the temperature of the boiler filling water which was originally achieved at 90C to 105C b. Closing the 3 LPSH blow up valve units -> Reducing steam losses in the process c. Repair of combustion air ducting and yoshimine boiler smoke gas lines 2 - > Increase boiler combustion air temperature. By implementing an energy efficiency program will benefit: a. At a Milled Capacity of 6,800 TCD, which was originally a surplus of 12 M IDR worth of bagasse, it became a surplus of 18.1 M IDR per milling season so that the total saving value was 6.1 M IDR per milling season and the DPMO value to Sigma Value was originally 3.45 to 3.51 b. At a Milled Capacity of 6,000 TCD, which was originally a 1.6 M IDR surplus of bagasse, it became a 7 M IDR surplus, so the total saving value was 5.4 M per milling season and the DPMO value to Sigma Value was originally 3.31 to 3.35 c. At a milled capacity of 5,500 TCD, which originally required a bagasse cost of 0.4 M IDR, a surplus of bagasse valued at 0.587 M IDR resulted in a total saving value of 4.7 billion per milling season and the DPMO value to Sigma Value was originally 3.23 to 3.26 Keywords: Saving Energy in Sugar Factory,Case Study,Lean Six Sigma

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Saving Energy Pabrik Gula, Case Study, Lean Six Sigma
Subjects:	T Technology > T Technology (General) > T57.5 Data Processing
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Raji Rachmadi
Date Deposited:	29 Jul 2023 01:11
Last Modified:	29 Jul 2023 01:11
URI:	http://repository.its.ac.id/id/eprint/100669

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