DAFTAR ISI

KATA PENGANTAR....................................................................................................... i
DAFTAR ISI ................................................................................................................... iii
DAFTAR TABEL .......................................................................................................... vii
DAFTAR GAMBAR .................................................................................................... viii
DAFTAR RUMUS .......................................................................................................... x
DAFTAR SIMBOL ........................................................................................................ xi

BAB I PENDAHULUAN................................................................................................ 1
1.1 Latar Belakang ......................................................................................................1
1.2 Lingkup Penelitian ................................................................................................ 2
1.3 Tujuan Penelitian ..................................................................................................3
1.4 Manfaat Penelitian ................................................................................................ 3

BAB II GAMBARAN UMUM PERUSAHAAN ..........................................................4

2.1 Gambaran Umum PT Semen Indonesia (Persero) Tbk.........................................4
2.1.1 Sejarah PT Semen Indonesia (Persero) Tbk ................................................4
2.1.2 Visi dan Misi PT Semen Indonesia (Persero) Tbk .......................................5
2.1.3 Tujuan PT Semen Indonesia (Persero) Tbk .................................................6
2.1.4 Lokasi PT Semen Indonesia (Persero) Tbk .................................................7
2.1.5 Struktur Organisasi PT Semen Indonesia (Persero) Tbk ............................. 8
2.1.6 Sistem Manajemen PT Semen Indonesia (Persero) Tbk.............................. 9
2.1.7 Produk PT Semen Indonesia (Persero) Tbk .................................................9
2.1.8 Anak Perusahaan PT Semen Indonesia (Persero) Tbk .............................. 14
2.2 Gambaran Umum Seksi Perencanaan Bahan dan Produksi................................ 16
2.2.1 Struktur Organisasi Seksi Perencanaan Bahan dan Produksi ....................16
2.2.2 Tugas Pokok Seksi Perencanaan Bahan dan Produksi .............................. 17
2.2.3 Penjelasan Singkat Seksi Perencanaan Bahan dan Produksi .....................19
2.3 Uraian Unit Kerja Praktik ...................................................................................20
2.3.1 Unit Kerja Seksi Pengelolaan Persediaan ..................................................20
2.3.2 Unit Kerja Perencanaan Persediaan ........................................................... 22

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 2.3.3 Unit Kerja Penerimaan Barang ..................................................................23
2.3.4 Unit Kerja Packer dan Pelabuhan .............................................................. 30
2.3.5 Unit Kerja Jaminan Mutu ..........................................................................33
2.3.6 Unit Kerja Pengendalian Proses ................................................................ 34
2.3.7 Unit Kerja Shipping ...................................................................................35
2.4 Spesifikasi Bahan Baku dan Bahan Tambahan Pembuatan Semen ....................36
2.4.1 Bahan Baku ................................................................................................ 36
2.4.1.1 Batu Kapur atau Limestone (CaCO3) .............................................36
2.4.1.2 Tanah Liat atau Clay (Al2SiO7xH2O) ............................................37
2.4.2 Bahan Tambahan ........................................................................................38
2.4.2.1 Pasir Silika .....................................................................................38
2.4.2.2 Gips atau Gypsum (CaSO42H2O) ..................................................38
2.4.2.3 Copper Slag ...................................................................................39
2.5 Proses Penyiapan Bahan Baku ............................................................................40
2.6 Proses Pembuatan Produk ...................................................................................40
2.6.1 Perbandingan Proses Pembuatan Produk ...................................................40
2.6.2 Pemilihan Proses Pembuatan Produk ........................................................41
2.6.3 Proses Pembuatan Produk secara Kering...................................................41
2.6.3.1 Crusher .......................................................................................... 42
2.6.3.2 Raw Mill......................................................................................... 43
2.6.3.3 Kiln (Pembakaran) .........................................................................43
2.6.3.4 Finish Mill......................................................................................43
2.7 Analisa Produk ....................................................................................................44

BAB III METODE PENELITIAN ..............................................................................45

3.1 Tempat dan Waktu Kerja Praktik ........................................................................45
3.2 Jurnal Kegiatan Kerja Praktik .............................................................................45
3.3 Metodologi Penelitian ......................................................................................... 48

BAB IV HASIL DAN PEMBAHASAN ......................................................................51

4.1 Identifikasi Permasalahan ...................................................................................51
4.2 Rumusan Masalah ............................................................................................... 52

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4.3 Tujuan Penelitian ................................................................................................ 52
4.4 Peramalan atau Forecasting ................................................................................53
4.4.1 Pengertian Peramalan ................................................................................53
4.4.2 Manfaat Peramalan ....................................................................................54
4.4.3 Model-model Peramalan ............................................................................55
4.4.4 Macam-macam Peramalan .........................................................................56
4.4.4.1 Metode Moving Averages .............................................................. 56
4.4.4.2 Metode Weighted Moving Averages ...............................................57
4.4.4.3 Metode Exponential Smoothing .....................................................57
4.4.4.4 Metode Double Exponential Smoothing ........................................59
4.4.5 Analisis Kesalahan Peramalan ...................................................................59
4.5 Software WinQSB ............................................................................................... 61
4.6 Inventory .............................................................................................................63
4.6.1 Pengertian dan Klasifikasi Inventory ......................................................... 63
4.6.2 Kegunaan Inventory ...................................................................................65
4.6.3 Fungsi Inventory ........................................................................................65
4.6.4 Pengawasan Inventory ...............................................................................66
4.6.5 Istilah dalam Inventory ..............................................................................66
4.6.5.1 EOQ (Economic Order Quantity) ..................................................66
4.6.5.2 EPQ (Economic Production Quantity) ..........................................70
4.6.5.3 ITO (Inventory Turn Over) ............................................................ 70
4.7 Diagram Fishbone (Cause and Effect)................................................................ 71
4.7.1 Pengertian Diagram Fishbone ...................................................................71
4.7.2 Manfaat Diagram Fishbone .......................................................................71
4.7.3 Cara Membuat Diagram Fishbone............................................................. 72
4.7.4 Kelebihan dan Kekurangan Diagram Fishbone .........................................73
4.8 Pengolahan Data .................................................................................................74
4.8.1 Pengolahan Data Forecasting Semen ........................................................74
4.8.1.1 Perhitungan dengan Menggunakan Microsoft Excel .....................75
4.8.1.2 Perhitungan dengan Menggunakan Software WinQSB .................78
4.8.2 Pengolahan Data Forecasting Terak .......................................................... 79
4.8.2.1 Perhitungan dengan Menggunakan Microsoft Excel .....................81

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 4.8.2.2 Perhitungan dengan Menggunakan Software WinQSB .................83
4.8.3 Pengolahan Data Inventory Bahan Tambahan ...........................................85
4.8.3.1 Perhitungan Inventory ..................................................................102
4.8.3.2 Analisa dengan Menggunakan Fishbone Diagram ......................103

BAB V PENUTUP.......................................................................................................108
5.1 Kesimpulan .......................................................................................................108
5.2 Saran .................................................................................................................109

DAFTAR PUSTAKA
LAMPIRAN

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 DAFTAR TABEL
Tabel 2.1 Komposisi Batu Kapur pada Pembuatan Semen Portland .......................... 37
Tabel 2.2 Komposisi Tanah Liat pada Pembuatan Semen Portland ............................ 37
Tabel 2.3 Komposisi Copper Slag pada Pembuatan Semen Portland ......................... 39
Tabel 2.4 Perbandingan Proses Pembuatan Produk ..................................................... 41
Tabel 3.1 Rincian Kegiatan Pelaksanaan Kerja Praktik .............................................. 45
Tabel 4.1 Data Historis Produksi Semen ..................................................................... 74
Tabel 4.2 Rekap Perhitungan Forecast untuk Produksi Semen (Ribuan Ton) ............ 75
Tabel 4.3 Rekap Data Perhitungan Error pada Produksi Semen ................................. 77
Tabel 4.4 Peramalan Produksi Semen Tahun 2015 ...................................................... 78
Tabel 4.5 Data Historis Produksi Terak ....................................................................... 80
Tabel 4.6 Rekap Perhitungan Forecast untuk Produksi Terak (Ribuan Ton) .............. 81
Tabel 4.7 Rekap Data Perhitungan Error .................................................................... 82
Tabel 4.8 Peramalan Produksi Terak 2015 .................................................................. 84
Tabel 4.9 Data Bahan Tambahan Gypsum ................................................................... 86
Tabel 4.10 Data Bahan Tambahan Batu Trass ............................................................... 90
Tabel 4.11 Data Bahan Tambahan Copper Slag ............................................................ 94
Tabel 4.12 Data Bahan Tambahan Pasir Silika .............................................................. 98
Tabel 4.13 Perbandingan Perhitungan pada Bahan Tambahan .................................... 102

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 DAFTAR GAMBAR
Gambar 2.1 Struktur Organisasi PT Semen Indonesia (Persero) Tbk........................... 8
Gambar 2.2 Semen Portland Tipe I ............................................................................ 10
Gambar 2.3 Semen Portland Tipe II ........................................................................... 10
Gambar 2.4 Semen Portland Tipe III...........................................................................11
Gambar 2.5 Semen Portland Tipe V ............................................................................11
Gambar 2.6 Portland Pozzolan Cement (PPC) ........................................................... 12
Gambar 2.7 Portland Composite Cement (PCC) ........................................................ 12
Gambar 2.8 Oil Well Cement (OWC) Class G HRC ................................................... 13
Gambar 2.9 Semen Thang Long PCB40 ..................................................................... 13
Gambar 2.10 Logo Semen Padang ................................................................................ 15
Gambar 2.11 Logo Semen Gresik ................................................................................. 15
Gambar 2.12 Logo Semen Tonasa ................................................................................ 15
Gambar 2.13 Logo Thang Long Cement ...................................................................... 15
Gambar 2.14 Struktur Organisasi Seksi Perencanaan Bahan dan Produksi.................. 17
Gambar 2.15 Alur Kerja Seksi Pengelolaan Persediaan ............................................... 21
Gambar 2.16 Struktur Organisasi Seksi Perencanaan Persediaan ................................ 23
Gambar 2.17 Struktur Organisasi Seksi Penerimaan Barang........................................ 24
Gambar 2.18 Prosedur Penerimaan Bahan Baku .......................................................... 29
Gambar 2.19 Prosedur Penerimaan Sparepart .............................................................. 30
Gambar 2.20 Prosedur Penerimaan Craft ..................................................................... 30
Gambar 2.21 Alur pada Unit Kerja Shipping ................................................................ 35
Gambar 2.22 Proses Produksi Pembuatan Semen ........................................................ 42
Gambar 3.1 Diagram Alir Penelitian........................................................................... 49
Gambar 4.1 Penggolongan Model-model Peramalan ................................................. 55
Gambar 4.2 19 Langkah Awal WinQSB ..................................................................... 62
Gambar 4.3 Tampilan Utama Forecasting .................................................................. 62
Gambar 4.4 Spesifikasi Problem Forecasting ............................................................ 62
Gambar 4.5 Tabel Pengisian Data Historis ................................................................. 62
Gambar 4.6 Forecasting Setup .................................................................................... 63
Gambar 4.7 Tabel Hasil Forecasting .......................................................................... 63

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Gambar 4.8 Model Grafis EOQ Sederhana ................................................................ 68
Gambar 4.9 Kurva Total Cost Minimum pada EOQ................................................... 69
Gambar 4.10 Grafik Jumlah Produksi Semen 2000-2014 ............................................ 75
Gambar 4.11 Grafik Hasil Perhitungan Forecasting Produksi Semen ......................... 76
Gambar 4.12 Grafik Tracking Signal Produksi Semen ................................................. 77
Gambar 4.13 Tabel Hasil Forecasting .......................................................................... 78
Gambar 4.14 Grafik Hasil Forecasting ......................................................................... 79
Gambar 4.15 Grafik Jumlah Produksi Terak 2000-2014 .............................................. 80
Gambar 4.16 Grafik Hasil Perhitungan Forecasting Produksi Terak ........................... 81
Gambar 4.17 Grafik Tracking Signal Produksi Terak ................................................... 83
Gambar 4.18 Tabel Hasil Forecasting .......................................................................... 84
Gambar 4.19 Grafik Hasil Forecasting ......................................................................... 85
Gambar 4.20 Grafik Data Bahan Tambahan Gypsum .................................................. 89
Gambar 4.21 Grafik Data Bahan Tambahan Batu Trass ............................................... 93
Gambar 4.22 Grafik Data Bahan Tambahan Copper Slag ............................................ 97
Gambar 4.23 Grafik Data Bahan Tambahan Pasir Silika ............................................ 101
Gambar 4.24 Fishbone Diagram ................................................................................. 103

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 DAFTAR RUMUS
Rumus 4-1 MA (Moving Average)............................................................................. 57
Rumus 4-2 WMA (Weighted Moving Average) ......................................................... 57
Rumus 4-3 Forecasting untuk Exponential Smoothing ............................................. 58
Rumus 4-4 Menghitung nilai trend ............................................................................ 58
Rumus 4-5 Menghitung Base Level ........................................................................... 59
Rumus 4-6 Expektasi Nilai Trend .............................................................................. 59
Rumus 4-7 MAD (Mean Absolute Deviation) ........................................................... 60
Rumus 4-8 MSE (Mean Square Error)...................................................................... 60
Rumus 4-9 MFE (Mean Forecast Error) ................................................................... 60
Rumus 4-10 MAPE (Mean Absolute Percentage Error) ............................................. 60
Rumus 4-11 CFE (Cumulative Forecast Error) .......................................................... 61
Rumus 4-12 Tracking Signal ....................................................................................... 61
Rumus 4-13 Nilai Q pada EOQ ................................................................................... 68
Rumus 4-14 Frekuensi Pemesanan .............................................................................. 68
Rumus 4-15 Holding Cost per Periode ........................................................................ 68
Rumus 4-16 Purchasing Cost per Periode ................................................................... 68
Rumus 4-17 Biaya Total Persediaan ............................................................................ 68
Rumus 4-18 Siklus Antar Pemesanan .......................................................................... 68
Rumus 4-19 Total Incremental Cost ............................................................................ 69
Rumus 4-20 Nilai Q pada EPQ ................................................................................... 70
Rumus 4-21 Setup Cost per Periode ............................................................................ 70
Rumus 4-22 Holding Cost per Periode........................................................................ 70
Rumus 4-23 ITO (Inventory Turn Over) ..................................................................... 70

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 DAFTAR SIMBOL

BESARAN SATUAN SIMBOL

Permintaan Setahun (Annual Demand) unit D
Permintaan Selama Waktu Ancang (Lead unit d
Time Demand)
Waktu Ancang (Lead Time) tahun LT
Ukuran Pemesanan (Order Quantity atau unit Q
Lot Size)
Tingkat Persediaan (Stock Level) unit SL
Rerata Tingkat Persediaan Setahun unit E{SL}
(Annual Stock Level Expectation)
Cadangan Pengaman (Safety Stock) unit SS
Tingkat Pemesanan Ulang (Re-Order unit ROP
Point)
Frekuensi Pesan (Frequency) kali-pesan F
Probabilitas Kekurangan Stok (Shortage P{d>ROP}
Probability)
Estimasi Kekurangan Stok (Shortage unit E{d>ROP}
Expectation)
Biaya Pemesanan (Setup Cost atau Rp / kali-pesan Cs
Ordering Cost)
Biaya Pembelian (Purchasing Cost) Rp / unit Cp
Biaya Simpan (Holding Cost) Rp / unit-tahun Ch
Biaya Kekurangan (Shortage Cost atau Rp / unit Cb
Backordering Cost)
Total Biaya Persediaan (Total Inventory Rp TIC
Cost)

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 DAFTAR PUSTAKA

Australian standard, “Methods for the Analysis and Testing of Coal and Cake”, 1994.

Fogarty, D.W., Blackstone. JH. Dan Hoffman, T.R., Production and Inventory
Management, South-Western Publishing Co., Cincinnati, 1991.

Gaspersz, Vincent. 2004. Production Planning and Inventory Control (PPIC):

Berdasarkan Pendekatan Sistem Perintegrasi MRP II dan JIT Menuju
Manufakturing 21. Jakarta: Gramedia Utama.

Hakim Nasution, Arman & Yudha Prasetyawan. 2008. Perencanaan Dan Pengendalian
Produksi.Graha Ilmu : Yogyakarta.

Hanke, John E., Wichern, Dean W. 2005. Business Forecasting. 8th Edition. Prentice
Hall, USA.

Parray E Kurt, “Cement Manufacture Hand Book”, Chemical Publishing Co Inc.,

NewYork, 1979.

Pwerry Robert H, Perry Chemical Engineer “s Hand Book”, 6th edition, Mc Graw-Hill,
NewYork, 1984.

Shreve, “Chemical Proses Industries”, 3rd edition, Mc Graw-Hill, NewYork, 1967.

Smith, Spencer B. 1989. “Computer Based Production and Inventory Control”. Prentice-
Hall.

Watson W, “Carddock Q. L.”, Cement Chemist and Works Manager “s Hand Book”, 2nd
edition, Concrete Publication Limited London.

, “Teknologi Semen”, Pusat Pendidikan dan Pelatihan PT Semen Gresik, 1983.

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