DETAIL KOLEKSI

Usulan Perencanaan Perawatan Preventive Maintenance Dan Persediaan Suku Cadang Dengan Pendekatan Reliability Centred Maintenance Ii Dan Reliability Centred Spares Pada Divisi Engine Plant Pt.misubishi Krama Yudha Motors And Manufacturing


Oleh : Andenan Dermawan Setiaji

Info Katalog

Penerbit : FTI - Usakti

Kota Terbit : Jakarta

Tahun Terbit : 2008

Pembimbing 1 : Docki Saraswati

Pembimbing 2 : Amal Witonohadi

Subyek : Machinery in industry - Maintenance and repair;Reliability (Engineering)

Kata Kunci : machine, preventive maintenance, planning, spare part, engine plant


File Repositori
No. Nama File Ukuran (KB) Status
1. 2008_TA_TI_06304099_Halaman-Judul.pdf 11950.21
2. 2008_TA_TI_06304099_Bab-1.pdf 2296.45
3. 2008_TA_TI_06304099_Bab-2.pdf 17143
4. 2008_TA_TI_06304099_Bab-3.pdf 3448.76
5. 2008_TA_TI_06304099_Bab-4.pdf 8963.21
6. 2008_TA_TI_06304099_Bab-5.pdf 33794.77
7. 2008_TA_TI_06304099_Bab-6.pdf 9190.16
8. 2008_TA_TI_06304099_Bab-7.pdf 1962.05
9. 2008_TA_TI_06304099_Daftar-Pustaka.pdf 435.76
10. 2008_TA_TI_06304099_Lampiran.pdf 56071.79

P PT. Mitsubishi Krama Yudha Motors And Manufacturing bagian Engine Plant merupakan sebuah perusahaan otomotif yang khusus memproduksi engine untuk berbagai jenis kendaraan roda empat keluaran Mitsubishi. Salah satu komponen mesin yang diproduksi pada lini machining PT MKM bagian Engine Plant adalah komponen crank shaft yang merupakan obyek pada penelitian•kali ini . Adapun permasalahan yang dihadapi oleh perusahaan adalah tingginya frekuensi kerusakan mesin pada lini crank shaft tersebut. Selain itu, sulG.t cadang yang dimiliki untuk komponen mesin produksinya masih kurang terkendali . Hal ini disebabkan oleh tidak mudahnya mengatur jadwal maintenance mesin-mesin produksi serta sulit dalam mengontrol persediaan suku cadang komponen mesin sehingga menghambat kelancaran jalannya proses produksi . Oleh karena itu diharapkan dengan menerapkan pendekatan Reliability Centered Maintenance II (RCM II) dan didukung oleh Reliability Centered Spares (RCS) permasalahan yang terjadi di perusahaan selama ini dapat teratasi .Langkah pertama untuk memecahkan permasalahan tersebut adalah denganmenentukan mesin kritis dari sejumlah mesin yang terdapat pada lini permesinan crank shaft dengan menggunakan diagram pareto. Lalu menentukan komponen kritis dari setiap mesin kritis yang telah terpilih dengan menggunakan diagram batang, melakukan kebijakan RCM II dengan mernbuat Failure Mode and Effect Analysis (FMEA) dan Root Cause Failure Analysis (RCFA), lalu membuat RCM Decision Worksheet. Setelah itu mengitung waktu antar kerusakan dan waktu perbaikan, menentukan distribusi waktu kerusakan dan perbaikan, menguji distribusi yang telah terpilih, mencari nilai MTTF dan MTTR dengan metode Maximum Likelihood Estimator (MLE), menghitung interval waktu penggantian, waktu pemeriksaan dan tingkat ketersediaan, menghitung reliabilitas kondisi sebelum dan sesudah penggantian pencegahan. Setelah itu melakukan kebijakan RCS yang diawali dengan pembuatan RCS Information Worksheet serta RCS Decision Worksheet, kemudian menghitung penurunan biaya antara biaya penggantian saat kerusakan dan sebelum kerusakan terjadi.Setelah dilakukan perhitungan maka diperoleh bahwa terdapat 8 buah mesin kritis dengan 14 buah komponen kritis. Untuk pembuatan FMEA diketahui bahwa mesin CS 150 memperoleh nilai RPN tertinggi, yaitu sebesar 432. Untuk kebijakan RCM didapatkan basil bahwa untuk komponen Jaw Chuck, ATC, PCB Bubble Memory, CRT mesin CS 150, Limit Switch V Block, Hose Vanishing Roller, CRT 180, Solenoid Dress System dan stopper Index Table masuk dalam kategori scheduled discard task sedangkan sisanya yaitu komponen V Block , Spindel Chuck, Arm Pin dan Transducer No.7 rn suk dalam kategori scheduled restoration task serta komponen Hydraulic Pump.. Motor masuk ke dalam kategori scheduled on condition task. Untuk interval waktu penggantian terbesar adalah komponen Limit Switch V Block sebesar 2515 jam , tingkat ketersediaan tertinggi adalah CRT pada mesin CS 150 sebesar 0.981960124 dan hampir semua komponen kritis memiliki nilai reliabilitas sama dengan 1 kecuali komponen mesin CS 170. Untuk kebijakan RCS diperoleh hasil bahwa komponen mesin CS 15 mesin CS 150, CRT 180, stopper Index Table dan Transducer No.7 sebaiknya di stok dalam gudang sedangkan untuk penurunan biaya perbaikan didapat komponen ATC dengan persentase penurunan biaya terbesar yaitu 97.18 %

P PT. Mitsubishi Krama Yudha Motors And Manufacturing especially Engine Plant division is an otomotive company which produces an engine for various type of mitsubishi' s motorbikes. This company also produces crank shaft, a part that formed the engine, at their machining line which will become our research focus in this thesis. High level of breakdown frequency from the machine at the crank shaft's machining line now becomes a problem in this company. Beside that, the spare part that this company has, still uncontrol at the best way. These problems come bacause of the unsuccesfull in controlling maintenance schedule for all the machines and their spare part inventory so that it causes the production process doesn't going well. Problem can be solved by using Reliability Centered Maintenance II (RCM II) and Reliability Centered Spares (RCS) approach.The first stage to solve the problem is tracking critical machine which will beidentified by using Pareto chart, tracking critical component using Bar chart. The second stage is conducting a scheme of maintenance procedure using RCM II approach, which started by making an Failure Mode and Effect Analysis (F.MEA), Root Cause Failure Analysis (RCFA), continued with RCM Decision Worksheet. After that , calculating TTF and TTR, distribution determination, distribution examination which have chosen, calculated MTTF and MTTR value with Maximum Likelihood Estimator methods, optimal replacement interval, inspection interval also availability, calculating reliability at the condition both before and after preventive replacement . After RCM II approach, we can start making an RCS Worksheet and RCS Decision Worksheet, continuing with reducing costs which overcome if they are approximating between failure maintenance's cost and preventive maintenance's cost.The results are 8 critical machines and 14 critical components . Based on FMEA, we know that CS 150 is the highest RPN machine with 432. The result from RCM approach for Jaw Chuck, ATC, PCB Bubble Memory, CRT in CS 150, Limit Switch VBlock, Hose Vanishing Roller, CRT 180, Solenoid Dress System dan stopper Index Table component classified in scheduled discard task the other component like V Block, Spindel Chuck, Arm Pin and Transducer No.7 classified in scheduled restoration task and Hydraulic Pump Motor classified in scheduled on condition task. While for the highest optimal replacement interval is Limit Switch V Block which has 2515 hours, highest availability is CRT in CS 150 with 0.981960124 percent, and almost all the component get 1 fot their reliability value except CS 170's components. For RCS Approach we get all the components in CS 150 and-•cs 180, stopper Index Table dan Transducer No.7 component better hold on local stock. Shortly, we can get ATC component with the highest reduced cost, which the percentage is until 97,18 %.

P PT. Mitsubishi Krama Yudha Motors And Manufacturing especially Engine Plant division is an otomotive company which produces an engine for various type of mitsubishi' s motorbikes. This company also produces crank shaft, a part that formed the engine, at their machining line which will become our research focus in this thesis. High level of breakdown frequency from the machine at the crank shaft's machining line now becomes a problem in this company. Beside that, the spare part that this company has, still uncontrol at the best way. These problems come bacause of the unsuccesfull in controlling maintenance schedule for all the machines and their spare part inventory so that it causes the production process doesn't going well. Problem can be solved by using Reliability Centered Maintenance II (RCM II) and Reliability Centered Spares (RCS) approach.The first stage to solve the problem is tracking critical machine which will beidentified by using Pareto chart, tracking critical component using Bar chart. The second stage is conducting a scheme of maintenance procedure using RCM II approach, which started by making an Failure Mode and Effect Analysis (F.MEA), Root Cause Failure Analysis (RCFA), continued with RCM Decision Worksheet. After that , calculating TTF and TTR, distribution determination, distribution examination which have chosen, calculated MTTF and MTTR value with Maximum Likelihood Estimator methods, optimal replacement interval, inspection interval also availability, calculating reliability at the condition both before and after preventive replacement . After RCM II approach, we can start making an RCS Worksheet and RCS Decision Worksheet, continuing with reducing costs which overcome if they are approximating between failure maintenance's cost and preventive maintenance's cost.The results are 8 critical machines and 14 critical components . Based on FMEA, we know that CS 150 is the highest RPN machine with 432. The result from RCM approach for Jaw Chuck, ATC, PCB Bubble Memory, CRT in CS 150, Limit Switch VBlock, Hose Vanishing Roller, CRT 180, Solenoid Dress System dan stopper Index Table component classified in scheduled discard task the other component like V Block, Spindel Chuck, Arm Pin and Transducer No.7 classified in scheduled restoration task and Hydraulic Pump Motor classified in scheduled on condition task. While for the highest optimal replacement interval is Limit Switch V Block which has 2515 hours, highest availability is CRT in CS 150 with 0.981960124 percent, and almost all the component get 1 fot their reliability value except CS 170's components. For RCS Approach we get all the components in CS 150 and-•cs 180, stopper Index Table dan Transducer No.7 component better hold on local stock. Shortly, we can get ATC component with the highest reduced cost, which the percentage is until 97,18 %.

Bagaimana Anda menilai Koleksi ini ?