Analisis Penurunan Risiko Kegagalan Pada Wastewater Treatment Plant PT XYZ Dengan Metode Fishbone Diagram dan Failure Mode and Effect Analysis (FMEA)

Kuntaraco, Bellarosa Delima (2025) Analisis Penurunan Risiko Kegagalan Pada Wastewater Treatment Plant PT XYZ Dengan Metode Fishbone Diagram dan Failure Mode and Effect Analysis (FMEA). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT XYZ merupakan salah satu pabrik yang bergerak di bidang industri pupuk dan non pupuk terbesar di Indonesia. PT XYZ memiliki tiga pabrik utama untuk menjalankan proses produksinya. Ketiga pabrik tersebut tentunya menghasilkan limbah cair setiap harinya. Limbah cair tidak dapat secara langsung dibuang ke lingkungan sehingga memerlukan pengolahan terlebih dahulu hingga memenuhi standar baku mutu. PT XYZ memiliki Wastewater Treatment Plant (WWTP) yang merupakan unit pengolahan air limbah. WWTP tersebut akan mengolah limbah cair dari pabrik I, pabrik II, dan limpasan pabrik III. Namun, risiko kegagalan pengolahan pada WWTP dapat terjadi akibat meningkatnya debit limbah yang diolah, kondisi air limbah yang diolah, dan kesalahan dari faktor manusia. Penelitian ini dilakukan untuk menganalisis dan mengidentifikasi potensi kegagalan pada WWTP PT XYZ dengan fishbone diagram dan Failure Mode and effect Analysis (FMEA). Guna mengetahui potensi penyebab kegagalan pada WWTP dilakukan penelitian dengan fishbone diagram. Dengan fishbbone diagram, dapat diketahui faktor penyebab dari permasalahan potensi kegagalan sistem di WWTP. Faktor penyebab meliputi sumber daya manusia (people), metode (methods), mesin (machines), bahan (materials), pengukuran (measurement), dan lingkungan (environment). Failure Mode and effect Analysis (FMEA) digunakan untuk identifikasi potensi penyebab kegagalan serta penentuan besaran nilai dari setiap resiko. Penentuan besaran nilai berdasarkan tingkat keparahan (severity), tingkat kejadian (occurrence), dan tingkat deteksi (detection). Ketiga penilaian tersebut akan dikalikan sehingga didapatkan Risk Priority Number (RPN) untuk menentukan risiko kegagalan dengan nilai tertinggi hingga terendah. Berdasarkan hasil penelitian didapatkan tiga risiko kegagalan dengan nilai RPN paling tinggi yaitu permasalahan pompa mengalami scaling karena adanya endapan berlebih dengan nilai RPN 30, mesin dan alat (flow meter, pH meter, pompa, injektor, agitator) mengalami overhaul sehingga terhenti sementara saat dilakukan proses perbaikan dengan nilai RPN 24, dan air limbah tercampur dengan air hujan dengan nilai RPN 18. Upaya penanganan risiko kegagalan dilakukan dengan pengadaan pompa cadangan, pemasangan sensor getaran pompa, perbaikan SOP terhadap penanganan kondisi kegagalan, penggantian mesin serta alat yang sudah menurun performanya, dan mendesain kapasitas maksimum WWTP melebihi kapasitas normal pengolahan.
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PT XYZ is one of the largest companies in Indonesia engaged in the fertilizer and nonfertilizer industries. PT XYZ operates three main factories to run production processes. These factories produce liquid waste every day. Liquid waste cannot be directly discharged into the environment, so it needs to be treated first until it meets the required quality standards. PT XYZ has a Wastewater Treatment Plant (WWTP), which is a wastewater treatment unit. The WWTP will process liquid waste from plant I, plant II, and plant III runoff. However, the risk of treatment failure at the WWTP can occur due to the increased volume of wastewater that need to be processed, the condition of the wastewater, and human errors. This research is conducted to analyze and identify potential failures in the WWTP at PT XYZ using the Fishbone Diagram and Failure Mode and Effect Analysis (FMEA). To identify potential causes of failure at the WWTP, a study was conducted using the Fishbone Diagram. Through the Fishbone Diagram, the contributing factors to potential system failure issues at the WWTP can be determined. These factors include human resources (people), methods, machines, materials, measurement, and environment. Failure Mode and Effect Analysis (FMEA) is used to identify the potential causes of failure and determine the magnitude of each risk. The risk magnitude is based on severity, occurrence, and detection levels. These three assessments are multiplied to obtain the Risk Priority Number (RPN) to rank the risks of failure from highest to lowest. Based on the research results, three failure risks with the highest RPN values were identified is scalling issues in the pump due to excessive sediment with RPN 30, machine and equipments (flow meter, pH meter, pump, injector, agitator) undergoing overhaul so causing temporary operational halts during repairs with RPN 24, and wastewater mixing with rainwater with RPN 18. Risk mitigation efforts include the provision of backup pump, installation of pump vibration sensor, improvement of Standar Operational Procedures (SOP) for failure handling, replacement of machines and equipments with declining performance, and designing the WWTP’s maximum treatment capacity to exceed normal operational capacity.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	WWTP, Fishbone Diagram, FMEA, Risiko, RPN WWTP, Fishbone Diagram, FMEA, Risk, RPN
Subjects:	T Technology > TD Environmental technology. Sanitary engineering > TD194.6 Environmental impact analysis
Divisions:	Faculty of Civil, Planning, and Geo Engineering (CIVPLAN) > Environmental Engineering > 25201-(S1) Undergraduate Thesis
Depositing User:	Bellarosa Delima Kuntaraco
Date Deposited:	22 Jul 2025 06:50
Last Modified:	22 Jul 2025 06:50
URI:	http://repository.its.ac.id/id/eprint/120487

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