Analisis Risiko dan Biaya Strategi Reverse Engineering untuk Obsolete Part: Studi Kasus di PLTU Paiton Unit 3, 7, dan 8

Pratama, Abdullah Nadhif Ersa (2024) Analisis Risiko dan Biaya Strategi Reverse Engineering untuk Obsolete Part: Studi Kasus di PLTU Paiton Unit 3, 7, dan 8. Masters thesis, Institut Teknologi Sepuluh Nopember.

Text 09211950084001-Master_Thesis.pdf - Accepted Version Restricted to Repository staff only until 1 July 2026. Download (1MB) | Request a copy

Abstract

Dengan memperhatikan isu pemanasan global dan transformasi menuju portofolio yang lebih sustainable dan growth-oriented beberapa perusahaan seperti GE (General Electric), Siemens, Toshiba, dan Mitsubishi Heavy Industries, memilih keluar dari bisnis coal-fired powerplant. Keluarnya beberapa perusahaan besar dari bisnis coal-fired power plant tersebut menimbulkan dampak terhadap ketersediaan spare part yang sudah tidak diproduksi dan tidak didukung lagi oleh perusahaan-perusahaan tersebut sehingga spare part yang berada di PLTU mengalami obsolensi sehingga dibutuhkan strategi dalam penyelesaian masalah obsolete part. Dalam penyelesaian masalah obsolete equipment terdapat strategi yang disebut reverse engineering. Penelitian ini bertujuan untuk membuat strategi implementasi berupa framework yang mengkaji dari nilai ekonomis dengan analisis kelayakan finansial yaitu NPV (Net Present Value), PI (Profitability Index) dan pengendalian risiko dari reverse engineering menggunakan HIRARC (Hazard Identification, Risk Assessment and Risk Control). Fokus penelitian ini yaitu obsolete part yaitu coal nozzle tip, gearbox mill, dan condenser tube plug yang sudah tidak diproduksi dan tidak didukung oleh perusahaan supplier OEM (Original Equipment Manufacturer) di PLTU Paiton Unit 3, 7, dan 8. Metode penelitian dilakukan dengan menggunakan HIRARC (Hazard Identification, Risk Assessment and Risk Control). Metode HIRARC terdiri dari identifikasi bahaya, penilaian risiko, dan pengendalian risiko. Identifikasi risiko dan penilaian risiko dilakukan menggunakan Matrix 5x5 Severity vs Impact. Dalam menentukkan prioritas masalah dengan menggunakan konsep ALARP (As Low As Reasonably Praticable). Penyusunan rancangan mitigasi risiko dilakukan untuk memberikan alternatif solusi terhadap risiko reverse engineering, sehingga mencapai standar ALARP. Untuk mengevaluasi kelayakan proyek menggunakan metode NPV (Net Present Value) dan PI (Profitability Index). Hasil penelitian menunjukkan bahwa proses reverse engineering spare part memiliki risiko terhadap kualitas, jadwal (schedule), harga, dan kerusakan barang saat beroperasi karena tidak tahan temperature tinggi. Mitigasi penurunan risiko difokuskan pada risiko terbesar yaitu kerusakan coal nozzle tip dan condenser tube plug saat beroperasi karena tidak tahan temperature tinggi yaitu dengan pengendalian risiko pemilihan material yang tepat tahan dengan temperature tinggi dan kerusakan karena kesalahan instalasi yaitu dengan pengendalian risiko memilih vendor yang tepat sesuai dengan kualifikasi instalasi gearbox mill, dan menunjukkan bahwa strategi reverse engineering dapat menurunkan biaya (cost saving) pengadaan coal nozzle tip, gearbox mill, dan condenser tube plug pada PLTU Paiton Unit 3, 7 dan 8 menggunakan analisa economic evaluation menggunakan net present value dan profitability index dengan hasil penghitungan cumulative PV masing-masing sebesar 29.469 USD, 17.980 USD, dan 3.877 USD dan hasil penghitungan nilai PI masing-masing sebesar 1,89, 1,05, dan 1,30 hal ini sangat layak dilakukan penggantian spare part menggunakan produk reverse engineering karena nilai masing-masing NPV > 0 dan hasil masing-masing nilai profitability index > 1
===================================================================================================================================
By paying attention to the issue of global warming and the transformation towards a more sustainable and growth-oriented portfolio, several companies, such as GE (General Electric), Siemens, Toshiba and Mitsubishi Heavy Industries, have chosen to exit the coal-fired powerplant business. The exit of several large companies from the coal-fired power plant business has had an impact on the availability of spare parts which are no longer produced and are no longer supported by these companies so that spare parts in the PLTU experience obsolescence so that a strategy is needed to resolve the obsolete part problem. In solving obsolete equipment problems, there is a strategy called reverse engineering. This research aims to create an implementation strategy in the form of a framework that examines economic value with financial feasibility analysis, namely NPV (Net Present Value), PI (Profitability Index) and risk control from reverse engineering using HIRARC (Hazard Identification, Risk Assessment and Risk Control). The focus of this research is obsolete parts, namely coal nozzle tip, gearbox mill, and condenser tube plug which are no longer produced and are not supported by the OEM (Original Equipment Manufacturer) supplier company at PLTU Paiton Units 3, 7, and 8. The research method was carried out using HIRARC (Hazard Identification, Risk Assessment and Risk Control). The HIRARC method consists of hazard identification, risk assessment, and risk control. Risk identification and risk assessment are carried out using the 5x5 Severity vs Impact Matrix. In determining problem priorities using the ALARP (As Low As Reasonably Practicable) concept. The preparation of a risk mitigation design is carried out to provide alternative solutions to the risk of reverse engineering, so as to achieve the ALARP standard. To evaluate the feasibility of the project using the NPV (Net Present Value) and PI (Profitability Index) methods. The research results show that the reverse engineering spare part process has risks to quality, schedule, price, and damage to goods during operation because they cannot withstand high temperatures. Risk reduction mitigation is focused on the biggest risk, namely damage to the coal nozzle tip and condenser tube plug during operation because they cannot withstand high temperatures, namely by controlling the risk of selecting the right material to withstand high temperatures and damage due to installation errors, namely by controlling the risk of choosing the right vendor in accordance with gearbox mill installation qualifications, and shows that the reverse engineering strategy can reduce costs (cost savings) of procurement of coal nozzle tip, gearbox mill, and condenser tube plug at PLTU Paiton Units 3, 7 and 8 using economic evaluation analysis using net present value and profitability index with the cumulative PV calculation results of 29,469 USD, 17,980 USD, and 3,877 USD respectively and the PI value calculation results of 1.89, 1.05, and 1.30 respectively, it is very feasible to replace spare parts using reverse products engineering because the value of each NPV is > 0 and the results of each profitability index value are > 1

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	manajemen risiko, HIRARC, reverse engineering, pengendalian risiko, analisis kelayakan finansial; risk management, HIRARC, reverse engineering, risk control, financial feasibility analysis
Subjects:	T Technology > T Technology (General) > T174.5 Technology--Risk assessment.
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Abdullah Nadhif Ersa Pratama
Date Deposited:	13 Feb 2024 06:15
Last Modified:	13 Feb 2024 06:15
URI:	http://repository.its.ac.id/id/eprint/107118

Actions (login required)

View Item