Analisis Reliabilitas Pada Subsistem Finish Mill Pabrik Semen

Qodriyah, Azzahro Lailatul (2025) Analisis Reliabilitas Pada Subsistem Finish Mill Pabrik Semen. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Proses produksi semen pada perusahaan produsen semen terbagi dalam tujuh area utama pada masing-masing pabrik, yaitu Crusher Area, Raw Mill Area, Kiln Area, Coal Mill Area, Finish Mill Area, Packer Area, dan Mobile Room Area. Finish Mill merupakan salah satu sistem paling krusial dalam produksi semen, karena kinerjanya sangat memengaruhi kapasitas produksi serta kualitas semen yang dihasilkan. Finish Mill pada pabrik ini terdapat 2 yaitu Finish Mill A dan Finish Mill B yang tersusun secara paralel di mana memiliki tipe yang sama yaitu Vertical mill. Dengan menggunakan failure modes and effect analysis terpilihlah Finish Mill B untuk dilakukan penelitian lebih dalam. Finish Mill terdiri atas 4 subsistem diantaranya Raw Material Feed Group, Mill Feed Group, Mill Group, dan Mill Product Group yang tersusun secara seri. Keandalan Finish Mill sangat mempengaruhi kinerja Finish Mill produksi semen sehingga perlu dilakukan perhitungan nilai keandalan Finish Mill B. Nilai reliabilitas masing-masing subsistem Finish Mill B tiap tahun mengalami penurunan. Penurunan nilai keandalan pada masing-masing subsistem berpengaruh pada nilai reliabilitas Finish Mill B secara keseluruhan. Dalam jangka waktu 720 jam, nilai reliabilitas subsistem Raw Material Feed Group sebesar 0,3937; Mill Feed Group sebesar 0,0190; Mill Group sebesar 0,0184; Mill Product Group sebesar 0,5782 serta nilai reliabilitas Finish Mill B secara keseluruhan mencapai 0,00001. Nilai ini menandakan reliabilitas yang sangat rendah. Reliabilitas suatu sistem atau produk yang menurun tiap tahun menandakan bahwa performa dan keandalannya semakin berkurang seiring waktu. Selain itu, Finish Mill B mengalami beberapa kali unplanned downtime pada tahun 2024. Oleh karena itu, penelitian ini membahas mengenai penentuan waktu optimum pemeliharaan preventif subsistem Finish Mill menggunakan metode Geometric Process. Waktu optimum untuk melakukan kegiatan pemeliharaan pada subsistem Raw Material Feed Group adalah ketika terjadi kerusakan ketiga dengan biaya sebesar Rp 267.065.482. Waktu optimum untuk melakukan kegiatan pemeliharaan pada subsistem Mill Feed Group adalah ketika terjadi kerusakan kesembilan dengan biaya sebesar Rp 592.554.219. Waktu optimum untuk melakukan kegiatan pemeliharaan pada subsistem Mill Group adalah ketika kerusakan kesembilan dengan biaya sebesar Rp 842.903.938.
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The cement production process in a cement manufacturing company is divided into sevenmain areas at each plant, namely the Crusher Area, Raw Mill Area, Kiln Area, Coal Mill Area, Finish Mill Area, Packer Area, and Mobile Room Area. Finish Mill is one of the most critical systems in cement production, as its performance greatly affects both production capacity and the quality of the cement produced. This plant has two Finish Mills, Finish Mill A and Finish Mill B, which are arranged in parallel and are of the same type, namely Vertical Mill. Based on a failure modes and effect analysis (FMEA), Finish Mill B was selected for further study. Finish Mill consists of four subsystems arranged in series: Raw Material Feed Group, Mill Feed Group, Mill Group, and Mill Product Group. The reliability of Finish Mill significantly influences the overall cement production performance, making it essential to calculate the reliability of Finish Mill B. The reliability values of each Finish Mill B subsystem decline over time. This degradation impacts the overall reliability of Finish Mill B. Within a period of 720 hours, the reliability values of the Raw Material Feed Group, Mill Feed Group, Mill Group, and Mill Product Group subsystems were 0.3937, 0.0190, 0.0184; and 0.5782, respectively, resulting in an overall reliability of Finish Mill B of only 0.00001. This indicates an extremely low reliability level. The declining reliability of a system or product over time reflects a decrease in its performance and dependability. In addition, Finish Mill B experienced several unplanned downtimes in 2024. Therefore, this study focuses on determining the optimal preventive maintenance intervals for the Finish Mill B subsystems using the Geometric Process method. The optimal maintenance time for the Raw Material Feed Group subsystem is at the third failure, with an associated cost of Rp 267,065,482. For the Mill Feed Group subsystem, the optimum maintenance occurs at the ninth failure, with a cost of Rp 592,554,219. Meanwhile, for the Mill Group subsystem, the optimal maintenance is at the ninth failure, with a cost of Rp 842,903,938.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Geometric Process, Finish Mill, Subsistem Finish Mill, Reliabilitas, FMEA, Geometric Process, Finish Mill, Finish Mill Subsystem, Reliability, FMEA.
Subjects:	T Technology > TS Manufactures T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering)
Divisions:	Faculty of Science and Data Analytics (SCIENTICS) > Statistics > 49201-(S1) Undergraduate Thesis
Depositing User:	Azzahro Lailatul Q
Date Deposited:	01 Aug 2025 03:38
Last Modified:	01 Aug 2025 03:38
URI:	http://repository.its.ac.id/id/eprint/125504

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