Studi Reliability Engineering Dan Maintenance Value Stream Mapping (MVSM) Untuk Meningkatkan Kehandalan Rotary Kiln Pada Industri Semen

Arifandy, Henry Yotama (2024) Studi Reliability Engineering Dan Maintenance Value Stream Mapping (MVSM) Untuk Meningkatkan Kehandalan Rotary Kiln Pada Industri Semen. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Kehandalan suatu mesin sangat dipengaruhi oleh strategi pemeliharaan yang digunakan. Secara umum strategi perawatan dikategorikan menjadi tiga yaitu, yaitu Corrective Maintenance (CM), Preventive Maintenance (PM) dan Predictive
Maintenance (PdM). Predictive Maintenance (PdM) adalah strategi pemeliharaan dimana aktivitas perawatan dilakukan dengan mengevaluasi dan menganalisa kondisi aktual dari peralatan berdasarkan data histori kerusakan, sehingga dapat
diprediksi waktu yang optimal untuk dilakukan aktivitas perawatan sebelum terjadinya kegagalan peralatan (failure).
Pada industri semen peran Rotary Kiln sangat critical sebagai unit penghasil clinker dimana Kehandalan equipment rotary kiln harus terjaga untuk menunjang operasional kiln yang continue. Identifikasi critical equipment berdasarkan data histori kerusakan dan failure mode menjadi salah satu faktor penting penunjang kehandalan Rotary kiln. Data histori kerusakan di dapat secara real-time dari
Technical Information System (TIS). Data tersebut kemudian dianalisa dengan pendekatan Reliability Engineering dan Maintenance Value Stream Mapping (MVSM). Hasil analisa Reliability adalah prediksi waktu sebelum terjadinya
kegagalan, mencegah terjadinya downtime sedangkan analisa MVSM mereview semua aktifitas perawatan yang tidak memberikan nilai tambah (non value added) karena akan menimbulkan kerugian pada perusahaan.
Terdapat enam critical equipment dengan nilai MTBF tertinggi yaitu Tyre Kiln (17614 jam) dan terendah Weight Feeder (3835 jam) dengan nilai Reliability total Rotary Kiln sistem sebesar 20.87 % pada 1650 jam operasional. Penurunan
nilai reliability Rotary kiln yang signifikan disebabkan oleh crack pada tyre kiln sehingga terjadi limitasi parameter operasi serta perlu dilakukan inspeksi dan
perbaikan setiap 68 hari sekali untuk mencegah terjadinya breakdown akibat crack propagation. Hasil analisa MVSM memberikan peningkatan pada Maintenance
cycle efficiency (MCE) equipment setelah dilakukan improvement activity dengan nilai tertinggi pada Raco system (19.03%) dan terendah Tyre Kiln (6.85%)
Kata kunci: Reliability, TIS, MTBF, MVSM, FMEA

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Good equipment reliability is greatly influenced by the maintenance strategy used. In general, the maintenance strategy are categorized into three namely, Corrective Maintenance (CM), Preventive Maintenance (PM) and
Predictive Maintenance (PdM). Predictive Maintenance (PdM) is a maintenance strategy where maintenance activities are carried out by evaluating and analyzing the actual condition of the equipment based on historical damage data so that the
optimal time for maintenance activity can be predicted before equipment failure occurs. In the cement industry, the role of Rotary Kiln is very critical as a clinker
producing unit where the reliability of rotary kiln equipment must be maintained to support continuous kiln operations. Identification of critical equipment based on
historical damage data and failure modes is one of the important factors supporting the reliability of Rotary kiln. Historical damage data is obtained in real-time from
the Technical Information System (TIS). The data is then analyzed using the Reliability Engineering and Maintenance Value Stream Mapping (MVSM) approaches. The results of the Reliability analysis are predictions of the time before
failure occurs, preventing downtime while the MVSM analysis reviews all maintenance activities that do not provide added value (non-value added) because they will cause losses to the company. There are six critical equipment with the highest MTBF value Tyre Kiln (17614 hours) and the lowest Weight Feeder (3835 hours) with a total Reliability
value of the Rotary Kiln system of 20.87 % at 1650 hours of operation. The significant decrease in the reliability value of the Rotary kiln was caused by cracks in the tire kiln, resulting in limitations operating parameters and the inspection and repair every 68 days to prevent breakdowns due to crack propagation. The results of the MVSM analysis provide an increase in the Maintenance cycle efficiency
(MCE) of the equipment after improvement activity was carried out with the highest value in the Raco system (19.03%) and the lowest in Tyre Kiln (6.85%)
Keywords: Reliability, TIS, MTBF, MVSM, FMEA

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Reliability, TIS, MTBF, MVSM, FMEA
Subjects:	T Technology > TJ Mechanical engineering and machinery > TJ174 Maintenance and repair of machinery
Divisions:	Faculty of Business and Management Technology > Management Technology > 61101-(S2) Master Thesis
Depositing User:	Henry Yotama Arifandy
Date Deposited:	05 Aug 2024 03:22
Last Modified:	05 Aug 2024 03:22
URI:	http://repository.its.ac.id/id/eprint/113190

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