Pengelolaan Spare Parts Inventory Dengan Metode Continuous Review, Periodic Review Dan Reliability Di Warehouse PT. XYZ

Ermawanto, Dedy (2020) Pengelolaan Spare Parts Inventory Dengan Metode Continuous Review, Periodic Review Dan Reliability Di Warehouse PT. XYZ. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. XYZ adalah salah satu perusahaan yang bergerak di bidang pertambangan di pulau Jawa. Peralatan produksi beroperasi secara berkelanjutan 24 jam untuk memenuhi permintaan konsumen. Salah satu hal yang memainkan peranan penting dalam maintenance peralatan utama produksi adalah ketersediaan spare parts. Karena permintaan untuk spare parts tidak diketahui terlebih dahulu secara pasti, maka harus disimpan di warehouse. Kondisi tersebut dapat memicu meningkatnya inventory spare parts. Di satu sisi ketersediaannya tetap dijaga untuk mengurangi biaya downtime, di sisi yang lain jumlahnya mempengaruhi biaya inventory. Permasalahan yang terjadi di warehouse PT. XYZ adalah tingkat ketersediaan spare parts yang sering terjadi stockout dan overstock. Peralatan utama berhenti karena stockout dari periode September 2017 sampai dengan September 2019 sebesar 790 jam atau setara dengan kerugian produksi sebesar IDR 128,9 Milyar. Di warehouse ada 1.111 item stock number spare parts, dengan nilai inventory di bulan September 2017 sebesar IDR 932,47 juta yang kemudian naik sebesar 87 kali sehingga inventory di bulan September 2019 sebesar IDR 81,91 milyar. Pengendalian inventory selama ini dilakukan dengan metode min-max, dimana formula untuk menentukan minimal stock adalah average (rata-rata) dari demand historis, sedangkan maksimal stock adalah average (rata-rata) dari demand historis ditambah dengan 70% average (rata-rata) dari demand historis, reorder point menggunakan acuan minimal stock. Dengan metode diatas, dalam prakteknya ketersedian spare parts masih belum optimal. Metode yang dilakukan dalam penelitian ini adalah klasifikasi ADI-CV, klasifikasi ABC, simulasi Monte Carlo, periodic review (R, s, S), continuous review (s, Q), dan juga mempertimbangkan aspek reliability. Performansi yang diamati yaitu service level dan total biaya persediaan. Hasil perbandingan service level dan total biaya persediaan antara kondisi awal perusahaan dengan berbagai metode tersebut untuk spare parts rutin (consumable) mengindikasikan kenaikan service level 3,08% dan adanya penghematan sebesar 41,40%, kemudian untuk spare parts non rutin terjadi kenaikan service level 6,54% dan adanya penghematan sebesar 23,88%. Penghematan yang dilakukan terhadap total biaya persediaan untuk keseluruhan spare parts didapatkan sebesar 18.381.122.900 (25,99%) dan kenaikan service level sebesar 4,81% menjadi 97,69%. =========================================================================================================== PT. XYZ is one of the companies engaged in mining in Java. Production equipment operates 24 hours a day to meet consumer demand. One of the things that plays an important role in the maintenance of main production equipment is the availability of spare parts. Because the demand for spare parts is not known in advance for certain, it must be stored in the warehouse. These conditions can trigger an increase inventory spare parts. On one hand, availability is maintained to reduce the cost of downtime, on the other hand the amount affects inventory costs. Problems that occur in the warehouse of PT. XYZ is the level of spare parts availability which often happens in stockout and overstock. The main equipment stopped because of the stockout from the period September 2017 to September 2019 amounting to 790 hours or equivalent to a production loss of IDR 128,9 billion. In the warehouse there are 1.111 item stock number spare parts, with an inventory value in September 2017 of IDR 932,47 million which then increased by 87 times so that inventory in September 2019 amounted to IDR 81,91 billion. Inventory control has been done so far using the min-max method, where the formula for determining minimum stock is the average of the historical demand, while the maximum stock is the average of the historical demand plus the 70% average from historical demand, reorder points use a minimum reference stock. With the method above, in practice the availability of spare parts still does not optimal. The method used in this research is the ADI-CV classification, ABC classification, Monte Carlo simulation, periodic review (R, s, S), continuous review (s, Q), and also consider aspects of reliability. The observed performance is service level and total inventory costs. The observed performance is service level and total inventory costs. The results of comparison of service level and total inventory costs between the existing conditions of the company with various methods for routine spare parts (consumables) indicate an increase in service level of 3,08% and a saving of 41,40%, then for non-routine spare parts an increase in service level 6,54% and savings of 23,88%. The savings made to the total inventory costs for all spare parts were 18.381.122.900 (25,99%) and the service level increase was 4,81% to 97,69%.

Item Type: Thesis (Masters)
Uncontrolled Keywords: klasifikasi ADI-CV, klasifikasi ABC, simulasi Monte Carlo, periodic review (R, s, S), continuous review (s, Q), dan reliability ADI-CV classification, ABC classification, Monte Carlo simulation, periodic review (R, s, S), continuous review (s, Q), and reliability.
Subjects: H Social Sciences > HD Industries. Land use. Labor > HD38.5 Business logistics--Cost effectiveness. Supply chain management. ERP
H Social Sciences > HD Industries. Land use. Labor > HD39.5 Industrial procurement.
H Social Sciences > HD Industries. Land use. Labor > HD55 Inventory control
Divisions: Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis
Depositing User: Dedy Ermawanto
Date Deposited: 19 Aug 2020 06:43
Last Modified: 19 Aug 2020 07:01
URI: http://repository.its.ac.id/id/eprint/79183

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