PUTRA, SHANDY SATRIA WANGSA (2023) PEMILIHAN STRATEGI PEMELIHARAAN MESIN BALL MILL MENGGUNAKAN METODE F-MARCOS (Studi Kasus: PT Indocement Tunggal Prakarsa Tbk Cirebon). Other thesis, UPN "Veteran" Yogyajarta.
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Abstract
xviii
ABSTRAK
PT Indocement Tunggal Prakarsa Tbk (PT INTP) adalah perusahaan
manufaktur semen yang mengalami peningkatan nilai downtime untuk mesin yang
berada di Plant 9 pada tahun 2022 sebesar 57%. Berdasarkan data yang diperoleh
dari perusahaan, 80% dari nilai downtime keseluruhan berasal dari mesin Ball Mill
CM9A, Ball Mill CM9B, dan Ball Mill CM9C, sehingga ketiga mesin tersebut
dijadikan objek penelitian. Peningkatan downtime menandakan mesin-mesin
produksi mengalami penurunan kinerja pemeliharaan baik efektivitas, maupun
reliabilitasnya dan dampaknya mengarah pada penurunan kualitas dan output
produksi. Kecenderungan terjadi penurunan kinerja mesin menyebabkan perlunya
dilakukan konfirmasi penurunan kinerja mesin lebih lanjut dan dilakukan risk
assesment. Perusahaan juga memerlukan alternatif-alternatif strategi pemeliharaan
yang sesuai dan tidak hanya dapat meningkatkan efektivitas mesin, tetapi juga
meningkatkan reliabilitas mesin.
Pengukuran kinerja mesin dan risk assesment dilakukan menggunakan
Equipment Performance and Reliability (EPR). Pemilihan alternatif strategi
pemeliharaan dilakukan berdasarkan Multi Attribute Decision Making (MADM)
dengan teknik Fuzzy Analytical Hierarchhy Process (F-AHP) dan Fuzzy
Measurement Alternatives and Ranking according to the Compromise Solution (F-
MARCOS). F-AHP digunakan untuk pembobotan kriteria dan F-MARCOS
digunakan untuk penilaian dan pemeringkatan kriteria. Kriteria yang digunakan
dalam penelitian ini adalah ketersediaan (C1), kecepatan putar mesin (C2), dan
frekuensi kerusakan (C3). Alternatif strategi pemeliharan yang diusulkan adalah
Time-Based Maintenance (A1), Usage-Based Maintenance (A2), Condition-Based
Maintenance (A3), dan Predictive Maintenance (A4).
Hasil penelitian menemukan bahwa tingkat performa pemeliharaan ketiga
mesin ball mill memiliki efektivitas mesin dengan nilai sedang dengan nilai rata-
rata machine effectiveness masing-masing adalah 62%, 63%, dan 63% dan
reliabilitas mesin dengan nilai buruk dengan nilai masing-masing sebesar 27%,
30%, dan 32%. Berdasarkan EPR, dengan performa pemeliharaan pada tingkat 4
disarankan untuk melakukan risk assesment dan menyusun strategi perbaikan
dengan mempertimbangkan risiko dan konsekuensi kegagalan. Penyebab utama
kinerja mesin yang buruk berdasarkan risk assessment adalah consecutive shutdown
yang disebabkan karena mesin lain (kiln) sedang dalam maintenance atau
breakdown. Penyebab lainnya adalah motor pompa saluran ke separator
mengalami trip dan power supply incoming transformer mengalami trip. Strategi
pemeliharaan terpilih adalah Condition-Based Maintenance (CBM) dengan nilai
0,3308. Beberapa rekomendasi implementasi CBM adalah memasang sensor
monitoring di seluruh sub sistem ball mill, melakukan berbagai analisis status mesin
untuk perencanaan pemeliharaan, mengintegrasikan Computerized Maintenance
Management Systems (CMMS) dan Decision Suport Systems (DSS) untuk
membantu pengambilan keputusan lebih cepat dan akurat alih-alih manual, serta
training staf dan karyawan tentang implementasi CBM baik secara teoritis, maupun
praktik.
Kata kunci: Pemilihan Strategi Pemeliharaan, MADM, F-MARCOS
xix
ABSTRACT
PT Indocement Tunggal Prakarsa Tbk (PT INTP) is a cement manufacturer
that has experienced an increasement in the downtime value for machines in Plant
9 in 2022 by 57%. Based on company data, 80% of the overall downtime comes
from the Ball Mill CM9A, Ball Mill CM9B, and Ball Mill CM9C machines, so these
three machines were used as research objects. Increased downtime means that
production machines experience a decrease in maintenance performance, both
effectiveness and reliability, and the impact leads to a decrease in quality and
production output. The tendency for machine performance to decline causes the
need to confirm further machine performance decline and carry out a risk
assessment. Company also need alternative maintenance strategies that are
appropriate and not only increase machine effectiveness, but also increase machine
reliability.
Machine performance measurements and risk assessments are carried out
using Equipment Performance and Reliability (EPR). The selection of alternative
maintenance strategies is carried out based on Multi Attribute Decision Making
(MADM) with the Fuzzy Analytical Hierarchy Process (F-AHP) technique and
Fuzzy Measurement Alternatives and Ranking according to the Compromise
Solution (F-MARCOS) technique. F-AHP is used for criteria weighting and F-
MARCOS is used for criteria assessment and ranking. The criteria used in this
research are availability (C1), machine rotation speed C2), and failure frequency
(C3). The proposed alternative maintenance strategies are Time-Based
Maintenance (A1), Usage-Based Maintenance (A2), Condition-Based Maintenance
(A3), and Predictive Maintenance (A4).
The result of this study found that the level of maintenance performance of
the three ball mill machines had medium machine effectiveness with average
machine effectiveness values of 62%, 63% and 63% respectively and machine
reliability with poor scores with each value of 27 %, 30%, and 32%. Based on EPR,
with maintenance performance at level 4 it is recommended to carry out a risk
assessment and develop a repair strategy by considering the risks and
consequences of failure. The main cause of poor machine performance based on
risk assessment is consecutive shutdowns caused by other machine (kiln) being
under maintenance or breakdown. Another cause is that the line pump motor to the
separator trips and the incoming transformer power supply trips. The selected
maintenance strategies are Condition-Based Maintenance (CBM) with value of
0.3308. Some recommendations for implementing CBM are installing monitoring
sensors throughout the ball mill sub-system, carrying out various machine status
analyzes for maintenance planning, integrating Computerized Maintenance
Management Systems (CMMS) and Decision Support Systems (DSS) to help make
decisions more quickly and accurately instead of manual, as well as training for
staff and employees regarding the implementation of CBM both theoretically and
practically.
Keywords: Maintenance Strategy Selection, MADM, F-MARCOS
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Maintenance Strategy Selection, MADM, F-MARCOS |
| Subjects: | H Social Sciences > HD Industries. Land use. Labor |
| Divisions: | Faculty of Engineering, Science and Mathematics > School of Engineering Sciences |
| Depositing User: | Eko Yuli |
| Date Deposited: | 07 Nov 2023 07:18 |
| Last Modified: | 07 Nov 2023 07:18 |
| URI: | http://eprints.upnyk.ac.id/id/eprint/38119 |
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