Perancangan Strategi Pemeliharaan Workshop I PT Barata Indonesia Menggunakan Lean Maintenance

Kusumaningrum, Dwi (2018) Perancangan Strategi Pemeliharaan Workshop I PT Barata Indonesia Menggunakan Lean Maintenance. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Maintenance merupakan aktivitas untuk menjaga, mengembalikan keandalan mesin sehingga mesin dapat digunakan kembali. Pada proses produksi Bogie di PT Barata Indonesia ditemukan downtime yang terkadang melewati batas maksimum perusahaan. Hal ini memicu kerugian perusahaan berupa tidak tercapainya target produksi dan pengiriman produk. Downtime yang melebihi batas dapat memicu timbulnya waste berupa availabilitas mesin berkurang, waktu tunggu produksi bertambah, inventori produksi bertambah, dan overproduction pada departemen maintenance. Aktivitas maintenance telah dilakukan namun unplanned downtime masih cukup tinggi sehingga dapat dijadikan indikasi bahwa aktivitas pemeliharaan masih memiliki waste dan berdampak pada biaya pemeliharaan yang timbul. Permasalahan terkait waste dalam aktivitas maintenance dapat diselesaikan menggunakan lean maintenance. Penelitian ini bertujuan untuk melakukan pembenahan terhadap aktivitas pemeliharaan workshop I berdasarkan lean maintenance. Tahapan lean maintenance meliputi perhitungan Overall Equipment Effectiveness (OEE), pemetaan value stream maintenance mapping, dan identifikasi maintenance waste. Analisis terhadap kondisi eksisting dilanjutkan dengan analisis six big losses dan maintenance waste menggunakan fault tree analysis untuk mendapatkan akar permasalahan. Hasil penentuan maintenance waste kritis berdasarkan analytical hierarchy processs adalah poor inventory management, poor maintenance, waiting for maintenance resources, under utilization of resources, dan unnecessary motion. Selain itu, hasil penentuan six big lossess kritis berupa idling and stoppages minor, dan reduced speed losses. Rekomendasi perbaikan berupa penentuan interval maintenance berdasarkan keandalan mesin dengan distribusi Weilbull 2 parameter didapatkan mean time between failure (MTBF) sebesar 109,45 jam dan mean time to repair (MTTR) sebesar 2,35 jam. Penentuan inventory sparepart policy berupa safety stock, economic quantity order (EOQ), dan reorder level untuk masing-masing komponen. Selain itu dilakukan perencanaan lean training untuk pengoperasian mesin, strategi 5S dalam area kerja departemen maintenance, dan pembuatan SOP untuk operasional mesin. ================ Maintenance is an activity to maintain and restore reliability of the machine so that the machine can be operating again. In bogie production process at PT Barata Indonesia found that sometimes downtime exceeds maximum limit. This problem triggering company loss by not achieving production target and late delivery. Downtime that exceeds the limit can lead to waste in availability, increased production waiting time, increased producton inventory, and overproduction in maintenance department. Maintenance activity has been done but unplanned downtime still high enough so that it can be an indication that maintenance activity still has waste and impact on maintenance cost. Waste related to the provlem in maintenance acivities can be solved using lean maintenance. This research aims to make improvement to the activities of maintenance in workshop I based on lean maintenance. Step lean maintenance consist of overall equipment effectiveness calculation, value stream maintenance mapping, maintenance waste identification. Analysis of the existing condition followed by analysis of six big losses and maintenance waste using fault tree analysis to get root of problem. The result of determining critical maintenance waste based on analytical hierarchy process is poor inventory management, poor maintenance, waiting for maintenance resources, under-utilization of resources, and unnecessary motion. In addition, the result of determination of six major losses critical is idling and minor stoppages, and reduced speed losses. the improvement recommendation is the determination of maintenance nterval based on the reliability of the machine with the distribution of Weibull 2 parameters obtained mean time between failure of 109,45 hours and mean time to repair of 2,35 hours. Determination of inventory sparepart policy in the form of safety stock, economic order quantity, and reorder level for each component. In addition, lean training is planned for machine operation, 5S strategy in maintenance department work area, and making SOP for machine operation.

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: Fault Tree Analysis, Lean Maintenance, Maintenance Waste Overall Equipment Effectiveness (OEE), Six Big Losses
Subjects: T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering)
Divisions: Faculty of Industrial Technology > Industrial Engineering > (S1) Undergraduate Theses
Depositing User: Kusumaningrum Dwi
Date Deposited: 22 Jan 2019 02:41
Last Modified: 22 Jan 2019 02:41
URI: http://repository.its.ac.id/id/eprint/53361

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