Rosyid, Abdoel (2024) Optimalisasi Maintenance Mesin Pendingin Berdasarkan Logbook Appsheet Menggunakan Metode Power Law Process. Case Study : PT Indofood Sukses Makmur.Tbk-Divisi Bogasari Flourmills Surabaya. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Industri makanan dan minuman pada era saat ini akan terus bersaing dalam mendapatkan peluang pasar yang mendukung keberlangsungan hidup (sustainability) industri tersebut. Kompetisi tersebut di dukung oleh efisiensi dan inovasi dalam proses produksinya, termasuk digitalisasi data. PT Indofood Sukses Makmur,Tbk-Divisi Bogasari Flourmills Surabaya merupakan industri yang menghasilkan tepung terigu dalam proses produksi, dan di dukung oleh tim Repair maintenance pada proses produksi tersebut. Digitalisasi yang dilakukan oleh tim Repair maintenance dengan cara merubah laporan logbook pada kertas ke dalam laporan excel/extensi csv melalui aplikasi appsheet yang dapat dilihat dengan mengakses alamat sheet tersebut. Mesin-mesin pendingin pada PT Indofood Sukses Makmur,Tbk-Divisi Bogasari Flourmills Surabaya merupakan mesin yang bekerja mendukung kelancaran proses produksi yang berjumlah 300 unit lebih. Strategi preventive maintenance yang dilakukan harus berubah untuk lokasi ini yang terjadwal pada awalnya routine maintenance 3 bulan sekali, dengan hasil penentuan rata-rata laju antar kerusakan yang terjadi pada mesin pendingin MCC Mill AB adalah 942 jam/1.3bulan dan pada mesin pendingin CCR jetty 972 jam/1.35bulan. preventive maintenance yang dilakukan harus di persempit menjadi 1 bulan sekali untuk kedua lokasi tersebut.Srategi predictive maintenance yang dilakukan tanpa adanya mesin pendingin cadangan bisa menimbulkan downtime produksi, dikarenakan komponen elektronik PLC,HMI dan inverter panel mengalami overheat. Sehingga muncul biaya tambahan downtime produksi,selain biaya jasa dan sparepart. Pada replacement model skema ini diperoleh kesimpulan komponen mesin pendingin memiliki waktu pergantian jika sudah mencapai 13,000 hours meter dan setelah kerusakan ke-13. Sehingga rata-rata total biaya akibat kerusakan dalam satu siklus jam operasional pemakaian komponen 13,000 hours meter adalah Rp 2,869,412,000. Sedangkan dengan menggunakan kebijakan optimum replacement model maka estimasi total biaya akibat kerusakan adalah Rp 657,812/ jam dan pada operasional 3934 hours serta optimal di ganti setelah kerusakan ke 11. Sehingga di dapatkan biaya optimasi perbaikan menjadi Rp. 2,587,831,885. Hal ini berarti kebijakan optimum predictive maintenance atau penggantian komponen dapat mengurangi biaya sebesar 10% atau Rp 281,580,114 untuk pemakaian 13.000 hours.
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The food and beverage industry in the current era will continue to compete for market opportunities that support the industry's sustainability. This competition is supported by efficiency and innovation in the production process, including data digitization. PT Indofood Sukses Makmur, Tbk-Bogasari Flourmills Surabaya Division is an industry that produces wheat flour in the production process, and is supported by a Repair Maintenance team in the production process. Digitization is carried out by the Repair Maintenance team with changing logbook reports on paper into Excel/CSV extension reports via the Appsheet application which can be viewed by accessing the sheet address. The cooling machines at PT Indofood Sukses Makmur, Tbk-Division of Bogasari Flourmills Surabaya are machines that work to support the production process and total installed more than 300 units. The preventive maintenance strategy carried out must change for these two locations which were initially scheduled for routine maintenance once every 3 months, with the results of determining that the average rate of damage occurring to the MCC Mill AB cooling machine was 942 hours/1.3 months and to the CCR jetty cooling machine. 972 hours/1.35months. Preventive maintenance carried out must be narrowed to once a month.Predictive maintenance strategies carried out without a backup cooling machine can cause production downtime, because the electronic components of the PLC, HMI and inverter panel overheat. So additional production downtime costs arise, apart from service and spare parts costs. In this replacement scheme model, it is concluded that the cooling engine components have a replacement time when they reach 13,000 hour meters and after the 13th failure. So the average total cost due to damage in one operational hour cycle of using 13,000 hours components is IDR 2,869,412,000. Meanwhile, by using the optimum policy replacement model, the total estimated cost due to damage is IDR 657,812/hour and at 3943 hours of operation meter, and its optimally replaced after at the 11th damage. So the optimal repair cost is IDR. 2,587,831,885. This means that the optimum predictive maintenance or component replacement policy can reduce costs by 10% or IDR 281,580,114 for 13,000 hour usage
| Item Type: | Thesis (Masters) |
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| Uncontrolled Keywords: | Mesin pendingin, Logbook Appsheet, MTTF, Maintenanance, Cooling machine, Power Law Process (PLP) |
| Subjects: | Q Science > QA Mathematics > QA276 Mathematical statistics. Time-series analysis. Failure time data analysis. Survival analysis (Biometry) |
| Divisions: | Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT) |
| Depositing User: | Abdoel Rosyid |
| Date Deposited: | 04 Jun 2024 10:03 |
| Last Modified: | 04 Jun 2024 10:03 |
| URI: | http://repository.its.ac.id/id/eprint/108022 |
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