Analisis Keputusan "Repair Or Replace" Pada Strategi Maintenance Pabrik Ghopo Tuban (Studi Kasus: PT Semen Indonesia (Persero) Tbk.)

Sulaiman, Sahda Rani (2025) Analisis Keputusan "Repair Or Replace" Pada Strategi Maintenance Pabrik Ghopo Tuban (Studi Kasus: PT Semen Indonesia (Persero) Tbk.). Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Keputusan untuk melakukan perbaikan (repair) atau penggantian (replace) peralatan industri merupakan faktor kunci dalam strategi pemeliharaan karena mempengaruhi keandalan sistem, efisiensi biaya operasional, dan kontinuitas produksi. Di PT Semen Indonesia (Persero) Tbk. Pabrik I Ghopo Tuban, pendekatan kuantitatif berbasis data belum diterapkan secara optimal dalam menetapkan strategi pemeliharaan peralatan kritis seperti crusher, raw mill, kiln, finish mill, dan packer. Penelitian ini bertujuan melakukan penentuan keputusan “Repair or Replace” dengan mengintegrasikan keandalan melalui distribusi Weibull dan biaya menggunakan replacement analysis defender versus challenger. Sebanyak 1.084 titik data kegagalan historis (2022–2024) diolah untuk mengestimasi parameter Weibull (β: 0,80–1,45; η: 1.200–1.800 jam), menghasilkan MTBF rata-rata 1.050 jam dan failure rate 0,002 kegagalan/jam. Selanjutnya, perhitungan EUAC menunjukkan bahwa opsi penggantian packer menurunkan biaya tahunan dari Rp 2,250 miliar menjadi Rp 1,740 miliar (penurunan 22,7%), sementara simulasi Reliability Block Diagram berbasis FBD memperlihatkan peningkatan availabilitas sistem dari 94,3 % menjadi 97,6 %. Hasil ini menegaskan efektivitas pendekatan Distribusi Weibull dalam mendukung keputusan Repair or Replace yang data-driven, serta memberikan rekomendasi strategi pemeliharaan yang lebih objektif, efisien, dan berkelanjutan bagi PT Semen Indonesia.
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Decisions to repair or replace industrial equipment are crucial in maintenance strategies, as they directly impact system reliability, operational cost efficiency, and production continuity. At PT Semen Indonesia (Persero) Tbk Plant I Ghopo Tuban, a fully data-driven quantitative approach has yet to be optimally applied to the maintenance of critical equipment—namely crushers, raw mills, kilns, finish mills, and packers. This study conducts a Repair-or-Replace Analysis by integrating Reliability assessment via the Weibull Distribution with Maintenance Cost evaluation using a defender-versus-challenger framework. A total of 1,084 historical failure data points (2022–2024) were processed to estimate Weibull parameters (β: 0.80–1.45; η: 1,200–1,800 hours), yielding an average MTBF of 1,050 hours and a failure rate of 0.002 failures per hour. Equivalent Uniform Annual Cost (EUAC) calculations reveal that replacing the packer reduces annual costs from Rp 2.250 billion to Rp 1.740 billion a 22.7% decrease while Reliability Block Diagram simulations based on the Functional Block Diagram demonstrate an increase in system availability from 94.3 % to 97.6 %. These findings confirm the effectiveness of the Weibull-based approach in supporting data-driven Repair-or-Replace decisions and offer objective, efficient, and sustainable maintenance recommendations for PT Semen Indonesia

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Analisis Penggantian, Biaya Pemeliharaan, Keandalan, Repair or Replace, Distribusi Weibull Maintenance Cost, Reliability, Repair or Replace, Replacement Analysis, Weibull Distribution
Subjects:	L Education > LB Theory and practice of education > LB2300 Higher Education T Technology > TS Manufactures > TS173 Reliability of industrial products T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering) T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Sahda Rani Sulaiman
Date Deposited:	30 Jul 2025 08:40
Last Modified:	30 Jul 2025 08:40
URI:	http://repository.its.ac.id/id/eprint/124087

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