Manajemen Persediaan Suku Cadang Lokomotif Berbasis Keandalan Dengan Pendekatan Simulasi

Rochim, Abdul Rochim (2026) Manajemen Persediaan Suku Cadang Lokomotif Berbasis Keandalan Dengan Pendekatan Simulasi. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Ketersediaan suku cadang merupakan faktor penting dalam menjaga keandalan operasional lokomotif. Permasalahan utama yang dihadapi Depo Lokomotif Sidotopo Daop 8 Surabaya adalah tingginya risiko kegagalan komponen dan ketidakpastian kebutuhan suku cadang yang dapat menyebabkan kekurangan persediaan serta downtime. Penelitian ini bertujuan mengembangkan model pengendalian persediaan berbasis keandalan untuk menentukan kebijakan persediaan yang mampu meminimalkan biaya dan meningkatkan tingkat pelayanan. Penelitian dilakukan pada empat komponen kritis lokomotif CC201, CC203 dan CC206, yaitu AEP5, Victaulic 3,5”, Deadman, dan Flexible Hose. Analisis keandalan menggunakan distribusi Weibull, sedangkan kebutuhan suku cadang disimulasikan dengan metode Monte Carlo sebanyak 1.000 iterasi. Tiga kebijakan persediaan dibandingkan, yaitu periodic review berbasis reliability, periodic Incremental review, dan Continuous Review Min-Max dengan variasi Service Level 80–95%. Evaluasi dilakukan berdasarkan total biaya persediaan, shortage, tingkat pelayanan, dan downtime. Hasil penelitian menunjukkan bahwa AEP5 memiliki nilai reliability tertinggi sebesar 0,4727, sedangkan Flexible Hose terendah sebesar 0,1370 pada horizon operasi 1.008 jam. Perbandingan ketiga skenario menunjukkan bahwa kebijakan Continuous Review Min-Max dengan Service Level 95% menghasilkan performa terbaik dan memperoleh peringkat biaya tertinggi pada seluruh komponen dibandingkan skenario Simulasi reliability dan Incremental. Kebijakan ini mampu meningkatkan fill rate, menekan shortage, serta menjaga availability sistem secara lebih efektif. Total biaya persediaan terbaik yang dihasilkan masing-masing sebesar Rp37.27 miliar untuk AEP5, Rp231.99 miliar untuk Victaulic 3,5”, Rp29.39 miliar untuk Deadman, dan Rp26.59 miliar untuk Flexible Hose. Lebih dari 92% total biaya berasal dari biaya downtime, menunjukkan bahwa pengendalian risiko kegagalan komponen memiliki pengaruh yang jauh lebih besar dibandingkan biaya pemesanan maupun penyimpanan. Integrasi analisis keandalan dan simulasi Monte Carlo mampu menghasilkan kebijakan persediaan yang lebih ekonomis, adaptif, dan efektif dalam mendukung keandalan operasi lokomotif.
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Spare parts availability is a critical factor in maintaining Locomotive reliability and operational continuity. At the Sidotopo Locomotive Depot, Regional Operation Division 8 Surabaya, challenges arise from the high risk of component failures and the uncertainty of spare parts demand, which can lead to stock shortages and costly downtime. This study aims to develop a reliability-based inventory management model to determine an optimal inventory policy that minimizes total inventory costs while improving Service Levels and component availability. The research focuses on four critical components of the CC201, CC203 and CC206 Locomotive: AEP5, 3.5-inch Victaulic, Deadman, and Flexible Hose. Component reliability was analyzed using the Weibull distribution, while spare parts demand was modeled through Monte Carlo simulation with 1,000 iterations to capture operational uncertainties. Three inventory control policies were evaluated and compared: reliability-based periodic review, periodic Incremental review, and Continuous Review Min-Max with Service Levels ranging from 80% to 95%. The policies were assessed based on total inventory cost, Shortage Quantity, service performance, availability, and downtime impact. The results indicate that AEP5 exhibits the highest reliability value (0.4727), whereas Flexible Hose shows the lowest reliability (0.1370) over an operating horizon of 1,008 hours. Comparative analysis of the three inventory scenarios reveals that the Continuous Review Min-Max policy with a 95% Service Level delivers the best overall performance, outperforming both the Simulasi reliability and periodic Incremental approaches. This policy improves fill rate, reduces shortages, and enhances system availability. The resulting total inventory costs were IDR 37.27 billion for AEP5, IDR 231.99 billion for Victaulic 3.5-inch, IDR 29.39 billion for Deadman, and IDR 26.59 billion for Flexible Hose. Furthermore, more than 92% of total inventory costs were attributed to downtime costs, highlighting that failure-risk mitigation has a significantly greater impact on inventory optimization than ordering or Holding Costs. These findings demonstrate that integrating reliability analysis with Monte Carlo simulation provides a more economical, adaptive, and effective inventory management strategy for supporting reliable Locomotive operations.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Keandalan, manajemen persediaan, suku cadang lokomotif, Monte Carlo, Min-Max Reliability, Inventory Management, Locomotive Spare Parts, Monte Carlo Simulation, Min-Max Policy.
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD55 Inventory control T Technology > T Technology (General) > T57.62 Simulation
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User:	Abdul Rochim
Date Deposited:	16 Jul 2026 01:34
Last Modified:	16 Jul 2026 01:34
URI:	http://repository.its.ac.id/id/eprint/135017

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