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Perencanaan Perawatan Mesin dengan Menggunakan Metode Markov

Chain untuk Menurunkan Biaya Perawatan


(Study Kasus Mesin Stassiun Putaran di PT.PG.Krebet Baaru I Bululawang
Malang)

TUGAS AKHIR

Diajukan Sebagai Salah Satu Syarat Untuk Memperoleh Gelar


Sarjana Teknik Pada Jurusan Teknik Industri Fakultas Teknik
Universitas Muhammadiyah Malang

Oleh :
NAMA : RENI YULIANTI
NIM

: 98540065

NIRM : 98.7.024.31211.19719

JURUSAN TEKNIK INDUSTRI


FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH MALANG
2003

LEMBAR PERSETUJUAN
TUGAS AKHIR

NAMA

: Reni Yulianti

NIM / NIRM : 98540065 / 98.7.024.31211.19719


FAKULTAS : Teknik
JURUSAN

: Industri

JUDUL

: PERENCANAAN

PERAWATAN

MENGGUNAKAN METODE

MESIN

DENGAN

MARKOV CHAIN UNTUK

MENURUNKAN BIAYA PERAWATAN (Study Kasus Mesin


Stasiun Putaran di PT. PG.Krebet Baru I Bululawang Malang)

Menyetujui dan Mengesahkan,

Pembimbing I

Pembimbing II

Ir Heri.M.Kholik , MT

Ilyas Masudin, ST
Mengetahui,
Ketua Jurusan Industri

Ir. Dyah Retno P, MT

DAFTAR ISI
Halaman
HALAMAN JUDUL ...................................................................................

LEMBAR PERSETUJUAN .......................................................................

ii

BERITA ACARA BIMBINGAN TUGAS AKHIR ..................................

iii

BERITA ACARA UJIAN TUGAS AKHIR ..............................................

iv

ABSTRAKSI .................................................................................................
SURAT KETERANGAN PENELITIAN...................................................

v
vi

KATA PENGANTAR .................................................................................

vii

DAFTAR ISI ...............................................................................................

ix

DAFTAR TABEL .......................................................................................

xi

DAFTAR GAMBAR ..................................................................................

xiii

DAFTAR LAMPIRAN...............................................................................

xiv

BAB I PENDAHULUAN
1.1. Latar belakang...............................................................................
1.2. Perumusan Masalah.......................................................................
1.3. Tujuan Penelitian............................................................................
1.4. Manfaat Penelitian..........................................................................
1.5. Batasan Masalah............................................................................
1.6. Asumsi asumsi ......................................................................... ..
1.7. Sistematika Penulisan ................................................................. ...

1
2
2
3
3
4
5

BAB II LANDASAN TEORI


2.1. Sistem Perawatan ..........................................................................
2.1.1. Pengertian Dan Tujuan Perawatan.......................................
2.1.2. Jenis-jenis Perawatan .........................................................
2.1.3. Model Peraawatan Ideal.....................................................
2.1.4. Kebijaksanaan Perawatan ..................................................
2.2. Klasifikasi Kondisi Kerusakan........................................................
2.3. Proses Markov Chain ....................................................................
2.3.1. Penaksiran Parameter Markov............................................
2.3.2. Kegunaan Probabilitas dan Keputusan Markov...................
2.4. Analisa Biaya.................................................................................

7
7
9
11
12
13
14
17
19
22

2.4.1. Biaya Penyelenggaraan Perawatan Pencegahan...................


2.4.2. Biaya Korektif....................................................................
2.4.3. Ekspektasi Biaya................................................................
2.5. Perhitungan Periode Pemeliharaan Mesin yang Optimal...................
BAB III METODOLOGI PENELITIAN
3.1. Survey Perusahaan........................................................................
3.2. Identifikasi Masalah dan Penentuan Tujuan....................................
3.3. Study Literatur..............................................................................
3.4. Pengumpulan Data........................................................................
3.5. Pengolahan Data...........................................................................
3.6 Perencanaan Perawatan Mesin dengan Metode Markov Chain......
3.7. Analisa Hasil................................................................................
3.8. Kesimpulan dan Saran..................................................................
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA
4.1. Pengumpulan.................................................................................
4.1.1. Data Jenis Mesin ................................................................
4.1.2. Data Mesin yang Mengalami Transisi Staatus Tiap Item.......
4.1.3. Data Mesin yang Berada pada Status Baaik, Kerusakan
Ringan,Sedang dan Berat....................................................
4.1.4. Data Waktu Pemeliharaan Pencegahan................................
4.1.5. Data Waktu Rata-rata Kerusakan Mesin ............................
4.1.6. Data Biaya Downtime.........................................................
4.2. Jenis-Jenis Perawatan yang Dilakukan Perusahaan.........................
4.2.1. Jenis-jenis Perawatan Pencegahan ......................................
4.2.2. Jenis-jenis Perawatan Perbaikan.........................................
4.3. Pengolahan Data............................................................................
4.3.1. Perhitungan Probabilitas Status Masing-masing Item............
4.3.2. Perhitungan Probabilitas Status untuk Perencanaan
Perawatan Usulan ..............................................................
4.3.3. Perhitungan Periode Pemeliharaan Mesin Optimal...............
BAB V ANALISA DATA
5.1. Probabilitas Transisi.......................................................................
5.2. Matriks Transisi Untuk Perencanaan Perawatan Usulan..................
5.3. Probabilitas Status dalam Keadaan Steady State ............................
5.4. Analisa Biaya .................................................................................

23
23
24
24
25
26
28
28
31
37
37
37

38
38
38
40
42
43
45
47
47
48
49
49
55
82

91
92
96
98

5.5. Analisa Periode Pemeliharaan Pencegahan......................................


5.6. Analisa Hasil..................................................................................

105
109

BAB VI KESIMPULAN DAN SARAN


6.1. Kesimpulan....................................................................................
6.2. Saran ............................................................................................

111
112

DAFTAR PUSTAKA
LAMPIRAN

DAFTAR GAMBAR

Halaman
Gambar 2.1 Skematis Himpunan Tertutup (Close Set).....................................

21

Gambar 3.1 Metodologi Pemecahan Masalah.................................................

27

DAFTAR TABEL

Halaman
Tabel 4.1 Tabel Transisi Status Mesin Putaran Batch ..................................
38
Tabel 4.2 Tabel Transisi Status Mesin Putaran Conti.....................................

39

Tabel 4.3 Tabel Transisi Status Mesin Bucket Elevator..................................

39

Tabel 4.4 Tabel Transisi Status Mesin Vibrating Screen ................................

40

Tabel 4.5 Tabel Jumlah Status Mesin pada Mesin Putaran Batch...................

40

Tabel 4.6 Tabel Jumlah Status Mesin pada Mesin Putaran Conti....................

41

Tabel 4.7 Tabel Jumlah Status Mesin pada Mesin Bucket Elevator................

41

Tabel 4.8 Tabel Jumlah Status Mesin pada Mesin Vibrating Screen...............

42

Tabel 4.9 Tabel Waktu Pemeliharaan Pencegahan.........................................

42

Tabel 4.10 Tabel Waktu rata-rata Kerusakan Mesin Putaran Batch.................

43

Tabel 4.11 Tabel Waktu rata-rata Kerusakan Mesin Putaran Conti.................

43

Tabel 4.12 Tabel Waktu rata-rata Kerusakan Mesin Bucket Elevator..............

44

Tabel 4.13 Tabel Waktu rata-rata Kerusakan Mesin Vibrating Screen.............

44

Tabel 4.14 Tabel Probabilitas Transisi Status Mesin Putaran Batch .................

50

Tabel 4.15 Tabel Probabilitas Transisi Status Mesin Putaran Conti..................

51

Tabel 4.16 Tabel Probabilitas Transisi Status Mesin Bucket Elevator..............

52

Tabel 4.17 Tabel Probabilitas Transisi Status MesinVibrating Screen...............

54

Tabel 5.1 Tabel Probabilitas Status Mesin Putaran Batch..............................

96

Tabel 5.2 Tabel Probabilitas Status Mesin Putaran Conti...............................

96

Tabel 5.3 Tabel Probabilitas Status Mesin Bucket Elevator ...........................

97

Tabel 5.4 Probabilitas Status Mesin Vibrating Screen....................................

97

Tabel 5.5 Tabel Periode Pemeliharaan Pencegahan Mesin Putaran Batch............

105

Tabel 5.6 Tabel Periode Pemeliharaan Pencegahan Mesin Putaran Conti............

106

Tabel 5.7 Tabel Periode Pemeliharaan Pencegahan Mesin Bucket Elevator...

107

Tabel 5.8 Tabel Periode Pemeliharaan Pencegahan Mesin Vibrating Screen...

108

Tabel 5.9 Tabel Hasil Penelitian Perawatan Usulan Terbaik............................

109

Tabel 5.10 Tabel Hasil Penelitian Periode Pemeliharaan Terbaik......................

110

DAFTAR LAMPIRAN

Lampiran A : Input Data Probabilitas Transisi Awal


Lampiran B : Probabilitas Status Awal
Lampiran C : Input Data Probabilitas Status Perencanaan Perawatan Usulan
Lampiran D : Probabilitas Status Perencanaan Perawatan Usulan
Lampiran E : Gambar Mesin Putaran Batch
Lampiran F : Gambar Mesin Putaran Conti
Lampiran G : Gambar Mesin Bucket Elevator
Lampiran H : Gambar Mesin Vibrating SCreen

DAFTAR LAMPIRAN

Lampiran A : Input Data Probabilitas Transisi Awal


Lampiran B : Probabilitas Status Awal
Lampiran C : Input Data Probabilitas Status Perencanaan Perawatan Usulan
Lampiran D : Probabilitas Status Perencanaan Perawatan Usulan

DAFTAR PUSTAKA

Buffa, Elwood s, Rakesh K. Sarin, Manajemen Operasi dan Produksi Modern,


Edisi kedelepan, Jilid 1, Penerbit Binarupa Aksara, Jakarta, 1996.
Hines, William W Probabilita dan Statistik Dalam Ilmu Rekayasa dan
Manajemen, Edisi kedua, Penerbit UI,1990.
Moerdokusumo A. Pengawasan Kualitas dan Teknologi Pembuatan Gula di
Indonesia. Penerbit ITB Bandung, 1993.
Rammakumar, R, Engineering Reliability Fundamental Aplication, Prentice
Hall, New Jersey, 1993.
Ross, Sheldon M. Introduction To Probability Models, California, 1985.
Siagian. P. Penelitian Operasional, Penerbit UI Press, Jakarta, 1987.
Sofyan Assauri, Manajemen Produksi, Edisi Keempat, Penerbit Fakultas
Ekonomi UI,1993.
Subagyo Pangestu, Marwan Asri, T Hani Handoko. Dasar-Dasar Operation
Research, Edisi kedua, Penerbit BPFE, Yogyakarta, 1986.
Taha , A. Hamdy, Riset Operasi, Jilid 2, Penerbit Binarupa Aksara, Jakarta, 1996
Tijm, Henk C. Stocastic Models, Amsterdam, 1995.
Tjuju T. Dimyati, Ahmad
Dimyati, Operations Research, Model-Model
Pengambilan Keputusan, Edisi Kedua Penerbit Sinar Baru Algesindo,
Bandung, 1987.

1.

Probabilitas Transisi Mesin Putaran Batch


Modules-1

Modules-2

Input Data

Solution

Options

Help - MKV

+-------------------- Transition Probabilities for Markov ---------------------+


From

To:

S1

S2

S3

S4

+------------+----------------------------------------------------------------
S1

[.8495

][.0333

][.0654

][.0515

S2

][.375

][.25

][.375

S3

][

][.75

][.25

S4

[1

][

][

][

+------------------------------------------------------------------------------

<

OK >

< PgUp >

< PgLt >

< PgRt >

< Help >

< Print >

< Cancel >

+------------------------------------------------------------------------------+

2.

Probabilitas Transisi Mesin Putaran Conti

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[.9084
][.0336
][.0393
][.0185
]

S2
[
][.2
][.7
][.1
]

S3
[
][
][.6666
][.3333
]

S4
[1
][
][
][
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

3.

Probabilitas Transisi Mesin Bucket Elevator

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.7778
][0.0555
][0.0833
][0.0833
]

S2
[0
][0.3333
][0.3333
][0.3333
]

S3
[0
][0
][0.5
][0.5
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------
< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+

4.

Probabilitas Transisi Mesin Vibrating Screen

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.8055
][0.0555
][0.0833
][0.0555
]

S2
[0
][0.3333
][0.3333
][0.3333
]

S3
[0
][0
][0.5
][0.5
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+
1.
Perencanaan perawatan usulan mesin putaran Batch
a.
Perawatan korektif pada status 4 dan perawatan Pencegahan status 3
Modules-1 Modules-2 Input Data Solution Options Help - MKV
+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.8495
][0.0333
][0.0654
][0.0515
]

S2
[0
][0.375
][0.25
][0.375
]

S3
[0
][1
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+

Perawatan korektif pada status 3 dan 4 serta perawatan Pencegahan status 2


Modules-1 Modules-2 Input Data Solution Options Help - MKV
+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.8495
][0.0333
][0.0654
][0.0515
]

S2
[1
][0
][0
][0
]

S3
[1
][0
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+
b.

Perawatan korektif pada status 4 dan perawatan Pencegahan status 2 dan 3

Modules-1

Modules-2

Input Data

Solution

Options

Help MKV

+-------------------- Transition Probabilities for Markov ---------------------+


From

To:

S1

S2

S3

S4

+------------+-----------------------------------------------------------------
S1

[0.8495

][0.0333

][0.0654

][0.0515

S2

[1

][0

][0

][0

S3

[0

][1

][0

][0

S4

[1

][0

][0

][0

+------------------------------------------------------------------------------

<

OK >

< PgUp >

< PgLt >

< PgRt >

< Help >

< Print >

< Cancel >

+------------------------------------------------------------------------------+

c.

Perawatan korektif pada status 3 dan 4

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.8495
][0.0333
][0.0654
][0.0515
]

S2
[0
][0.375
][0.25
][0.375
]

S3
[1
][0
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+

Perencanaan perawatan usulan mesin putaran Conti


d.

Perawatan korektif pada status 4 dan perawatan Pencegahan status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.9084
][0.0336
][0.0393
][0.0185
]

S2
[0
][0.2
][0.7
][0.1
]

S3
[0
][1
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+
e.
Perawatan korektif pada status 3 dan 4 serta perawatan Pencegahan status 2
Modules-1 Modules-2 Input Data Solution Options Help MKV
+-------------------- Transition Probabilities for Markov --------------------+
From \ To:
S1
S2
S3
S4

+------------+----------------------------------------------------------------
S1
[0.9084
][0.0336
][0.03935
][0.0185
]

S2
[1
][0
][0
][0
]

S3
[1
][0
][0
][0
]

S4
[1
][0
][0
][0
]

+-----------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+-----------------------------------------------------------------------------+

f.

Perawatan korektif pada status 4 dan perawatan Pencegahan status 2 dan 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.9084
][0.0336
][0.0394
][0.0185
]

S2
[1
][0
][0
][0
]

S3
[0
][1
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+
g.

Perawatan korektif pada status 3 dan 4

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.9084
][0.0336
][0.0394
][0.0185
]

S2
[0
][0.2
][0.7
][0.1
]

S3
[1
][0
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+

2.
a.

Perencanaan perawatan usulan mesin Bucket Elevator


Perawatan korektif pada status 4 dan perawatan Pencegahan status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[.7778
][.0555
][.0833
][.0833
]

S2
[
][.3333
][.3333
][.3333
]

S3
[
][1
][
][
]

S4
[1
][
][
][
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+
b.

Perawatan korektif pada status 3 dan 4 serta perawatan Pencegahan status 2


Modules-1 Modules-2 Input Data Solution Options Help - MKV
+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.7778
][0.0555
][0.0833
][0.0833
]

S2
[1
][0
][0
][0
]

S3
[1
][0
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+

c.

Perawatan korektif pada status 4 dan perawatan Pencegahan status 2 dan 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.7778
][0.0555
][0.0833
][0.0833
]

S2
[1
][0
][0
][0
]

S3
[0
][1
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+
d.

Perawatan korektif pada status 3 dan 4

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.7778
][0.0555
][0.0833
][0.0833
]

S2
[0
][0.3333
][0.3333
][0.3333
]

S3
[1
][0
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+

3.
a.

Perencanaan perawatan usulan mesin Vibrating Screen


Perawatan korektif pada status 4 dan perawatan Pencegahan status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.8055
][0.0555
][0.0833
][0.0555
]

S2
[0
][0.3333
][0.3333
][0.3333
]

S3
[0
][1
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+----------------------------------------------------------------------------b.

Perawatan korektif pada status 3 dan 4 serta perawatan Pencegahan status 2


Modules-1 Modules-2 Input Data Solution Options Help - MKV
+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.8055
][0.0555
][0.0833
][0.0555
]

S2
[1
][0
][0
][0
]

S3
[1
][0
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+

c.

Perawatan korektif pada status 4 dan perawatan Pencegahan status 2 dan 3

Modules-1 Modules-2 Input Data Solution Options Help MKV


+-------------------- Transition Probabilities for Markov ---------------------+
From \ To:
S1
S2
S3
S4

+------------+-----------------------------------------------------------------
S1
[0.8055
][0.0555
][0.0833
][0.0555
]

S2
[1
][0
][0
][0
]

S3
[0
][1
][0
][0
]

S4
[1
][0
][0
][0
]

+------------------------------------------------------------------------------

< OK >
< PgUp > < PgLt > < PgRt > < Help > < Print > < Cancel >

+------------------------------------------------------------------------------+

d.

Perawatan korektif pada status 3 dan 4


Modules-1

Modules-2

Input Data

Solution

Options

Help - MKV

+-------------------- Transition Probabilities for Markov ---------------------+


From

To:

S1

S2

S3

S4

+------------+-----------------------------------------------------------------
S1

[0.8055

][0.0555

][0.0833

][0.0833

S2

[0

][0.3333

][0.3333

][0.3333

S3

[1

][0

][0

][0

S4

[1

][0

][0

][0

+------------------------------------------------------------------------------

<

OK >

< PgUp >

< PgLt >

< PgRt >

< Help >

< Print >

< Cancel >

+------------------------------------------------------------------------------+

1. Mesin Putaran Batch


Modules-1

Modules-2

Input Data

Solution

Options

Help - MKV

+---------------------- Solution of Period 6 for Markov ----------------------+


05-09-2003 13:14:02
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.6462998
M
S3
.217383

S2
0.034021
M
S4
.1013519
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

2. Mesin Putaran Conti


Modules-1 Modules-2 Input Data Solution Options Help - MKV
+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:18:05
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1

.6902934
M
S3
0.097613
M

S2

0.028675
M
S4
0.054631
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

3. Mesin Bucket Elevator


Modules-1 Modules-2 Input Data Solution Options Help - MKV
+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:32:03
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.6549399
M
S3
.1452844
M

S2
0.054114
M
S4
.1452844
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+----------------------------------------------------------------------------+
4. Mesin Vibrating Screen
Modules-1 Modules-2 Input Data Solution Options Help - MKV
+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:35:58
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.6669943
M
S3
.1478442
M

S2
0.055145
M
S4
.1293078
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

1.

Mesin putaran Batch

a.

Perawatan korektif pada status 4 dan perawatan pencegahan pada status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:40:34

Page: 1 of 1

+-----------------------------------------------------------------------------

State

Name

State Recurrence
Probability

Time

State

Name

State Recurrence
Probability

Time

+------------+------------+------------+------------+------------+------------

S1

.6334749

S3

.087007

S2

.1772188

S4

.1013933

+-----------------------------------------------------------------------------

Expected Cost/Profit =

Elapsed CPU Seconds =

+-----------------------------------------------------------------------------

< PageDown >

< PageUp >

< Hardcopy >

< Cancel >

+-----------------------------------------------------------------------------+

b.
Perawatan korektif pada status 3 dan 4 serta perawatan pencegahan pada status 2
Modules-1 Modules-2 Input Data Solution Options Help - MKV
+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:43:36
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.8681579
M
S3
0.056795
M

S2
0.028919
M
S4
0.044724
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds = 0.058593

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+
c.
Perawatan korektif pada status 4 dan perawatan pencegahan pada status 2 dan status 3
Modules-1 Modules-2 Input Data Solution Options Help - MKV
+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:45:52
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.8216674
M
S3
0.053778
M

S2
0.080915
M
S4
0.042348
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

d.

Perawatan korektif pada status 3 dan 4

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:50:05
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.8294982
M
S3
0.065394
M

S2
0.044375
M
S4
0.059462
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

2.
a.

Mesin Putaran Conti


Perawatan Korektif pada status 4 dan perawatan pencegahan pada status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:48:14
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.4451803
M
S3
.2283601
M

S2
.2877862
M
S4
0.038418
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

b.

Perawatan Korektif pada status 3 dan 4 serta perawatan pencegahan pada status 2

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:50:10
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.9157156
M
S3
0.036082
M

S2
0.030771
M
S4
0.016942
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

c.

Perawatan Korektif pada status 4 dan perawatan pencegahan pada status 2 dan status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:51:20
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.8839018
M
S3
0.034828
M

S2
0.0644605
M
S4
0.016353
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

d.

Perawatan Korektif pada status 3 dan 4

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 13:52:29
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.8818098
M
S3
0.060679
M

S2
0.037041
M
S4
0.020019
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

3.
a.

Mesin Bucket elevator


Perawatan Korektif pada status 4 dan perawatan pencegahan pada status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 14:18:52
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.5284809
M
S3
.1218202
M

S2
.2274538
M
S4
.1218202
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

b.
Perawatan Korektif pada status 3 dan 4 serta perawatan pencegahan pada status 2
Modules-1 Modules-2 Input Data Solution Options Help - MKV
+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 14:22:17
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.8178198
M
S3
0.068161
M

S2
0.045413
M
S4
0.068161
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+
c.
Perawatan Korektif pada status 4 dan perawatan pencegahan pada status 2 dan 3
Modules-1 Modules-2 Input Data Solution Options Help - MKV
+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 14:24:11
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.7657018
M
S3
0.063900
M

S2

.106092
M
S4
0.063900
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

d.

Perawatan Korektif pada status 3 dan 4

Modules-1 Modules-2 Input Data Solution Options Help MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 14:29:14
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.7656842
M
S3
0.085046
M

S2
0.063762
M
S4
0.085046
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

4.
a.

Mesin Vibrating Screen


Perawatan korektif pada status 4 dan perawatan pencegahan pada status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 14:36:03
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.5371915
M
S3
.1233632
M

S2
.2302176
M
S4
.1085247
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

b.

Perawatan korektif pada status 3 dan 4 serta perawatan pencegahan pada status 2

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 14:40:12
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.8364975
M
S3
0.069708
M

S2
0.046444
M
S4
0.046444
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

c.

Perawatan korektif pada status 4 dan perawatan pencegahan pada status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 14:42:57
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.7821409
M
S3
0.065253
M

S2
.1083024
M
S4
0.043476
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

+-----------------------------------------------------------------------------+

d.

Perawatan korektif pada status 4 dan perawatan pencegahan pada status 3

Modules-1 Modules-2 Input Data Solution Options Help - MKV


+---------------------- Solution of Period 6 for Markov ----------------------+
05-09-2003 14:45:15
Page: 1 of 1
+-----------------------------------------------------------------------------

State

State
Recurrence
State

State
Recurrence

Name
Probability
Time

Name
Probability
Time

+------------+------------+------------+------------+------------+------------

S1
.7820116
M
S3
0.086865
M

S2
0.065124
M
S4
0.065124
M
+-----------------------------------------------------------------------------

Expected Cost/Profit =
0
Elapsed CPU Seconds =
0

+-----------------------------------------------------------------------------

< PageDown >


< PageUp >
< Hardcopy >
< Cancel >

5.5. Analisa Periode Pemeliharaan pencegahan


1. Mesin Putaran Batch
Tabel 5-5
Periode Peme liharaan Pencegahan
(1)

(2)

(3)

(4)

(5)

(6)

Siklus

Perkiraan

Jumlah rata-

Perkiraan biaya

Perkiraan biaya PM

Perkiraan biaya

pemeliharaan

kerusakan

rata

kerusakan bulanan

bulanan

bulanan masing-

preventif (n)

dalam siklus

kerusakan/bln

(kol 3 x Rp.

(Rp.671.900x7)/kol 1

masing siklus PM

Bln

PM, Bi

(kol 2/kol 1)

14.326.500)

2.8
2.8
40114200
1
6.72
3.36
48137040
2
12.21
4.07
58308855
3
19.89
4.9725
71238521
4
27.96
5.592
80113788
5
44.63
7.438333
1.07E+08
6
Biaya perawatan pencegahan (Cost Preventive Maintenance / CPM) = Rp. 671.900
Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 14.326.500
Periode pemeliharaan preventif biaya minimum adalah setiap satu bulan sekali

(kol 4 + kol 5)
4703300
2351650
1567767
1175825
940660
783883.3

44817500
50488690
59876622
72414346
81054448
1.07E+08

2. Mesin Putaran Conti


Tabel 5-6
Periode Pemeliharaan Pencegahan
(1)

(2)

(3)

(4)

(5)

(6)

Siklus

Perkiraan

Jumlah rata-

Perkiraan biaya

Perkiraan biaya PM

Perkiraan biaya

pemeliharaa

kerusakan dalam

rata

kerusakan bulanan

bulanan

bulanan masing-

n preventif

siklus PM, Bi

kerusakan/bln

(kol 3xRp.

(Rp.679.100x7)/kol 1

masing siklus PM (kol

(kol 2/kol 1)

24.571.593,75)

(n) Bln

2.2
2.2
54057506
1
4.84
2.42
59463257
2
8.23
2.743333
67408072
3
15.81
3.9525
97119224
4
17.22
3.444
84624569
5
22.86
3.81
93617772
6
Biaya perawatan pencegahan (Cost Preventive Maintenance / CPM) = Rp. 679.100
Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 24.571.593,75
Periode pemeliharaan preventif biaya minimum adalah setiap satu bulan sekali

4 + kol 5)
7470100
3735050
2490033
1867525
1494020
1245017

61527606*
63198307
69898106
98986749
86118589
94862789

3. Mesin Bucket Elevator


Tabel 5-7
Periode Pemeliharaan Pencegahan
(1)

(2)

(3)

(4)

(5)

(6)

Siklus

Perkiraan

Jumlah rata-

Perkiraan biaya

perkiraan biaya PM

Perkiraan biaya

pemeliharaan

kerusakan

rata

kerusakan bulanan

bulanan (Rp.307.500 x

bulanan masing-

preventif (n)

dalam siklus

kerusakan/bln

(kol 3 x Rp.

7) /kol 1

masing siklus PM

Bln

PM, Bi

(kol 2/kol 1)

52.954.122,7)

1
0,9
0,9
47658710,43
2
2,07
1,035
54807516,99
3
3,59
1,196667
63368433,5
4
5,57
1,3925
73738615,86
5
8,14
1,628
86209311,76
6
6,98
1,163333
61603296,07
Biaya perawatan pencegahan (Cost Preventive Maintenance / CPM) = Rp. 307.500
Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 52.954.122,7
Periode pemeliharaan preventif biaya minimum adalah setiap satu bulan sekali

(kol 4 + kol 5)
922500
461250
307500
230625
184500
153750

48581210,43 *
55268766,99
63675933,5
73969240,86
86393811,76
61757046,07

4. Mesin Vibrating Screen


Tabel 5-8
Periode Pemeliharaan Pencegahan
(1)

(2)

(3)

(4)

(5)

(6)

Siklus

Perkiraan

Jumlah rata-rata

Perkiraan biaya

perkiraan biaya PM

Perkiraan biaya

pemelihar

kerusakan dalam

kerusakan/bln

kerusakan bulanan

bulanan

bulanan masing-

aan

siklus PM, Bi

(kol 2/kol 1)

(kol 3 x Rp.

(Rp.307.500x7)/kol1

masing siklus PM

preventif

32.373.000)

(kol 4 + kol 5)

(n) Bln
1
3,5
3,5
50142750
2
8,75
4,375
62678437,5
3
16,63
5,543333
79416565
4
28,44
7,11
101861415
5
46,16
9,232
132262248
6
72,74
12,12333
173684935
Biaya perawatan pencegahan (Cost Preventive Maintenance / CPM) = Rp. 307.500
Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 32.373.000
Periode pemeliharaan preventif biaya minimum adalah setiap satu bulan sekali

4703300
2351650
1567767
1175825
940660
783883,3

54846050*
65030087,5
80984331,67
103037240
133202908
174468818,3