Daftar Isi

Skripsi
Jurusan Teknik Industri
DAFTAR ISI
Halaman
HALAMAN JUDUL
LEMBAR PENGESAHAN
KATA PENGANTAR ........................................................................................... i
DAFTAR ISI........................................................................................................ iii
DAFTAR TABEL................................................................................................ vi
DAFTAR GAMBAR........................................................................................... vii
DAFTAR PERSAMAAN.................................................................................. viii
DAFTAR PERSAMAAN.................................................................................. viii
SARI ...................................................................................................................... ii
ABSTRACK ......................................................................................................... ii
BAB I PENDAHULUAN
1.1 Latar Belakang 1
1.2.........................................................................................Rumusan Masalah
...........................................................................................................................4
1.3 Tujuan Penelitian ................................................................................. 4
1.4 Manfaat Penelitian ............................................................................... 4
1.5 Batasan Masalah ................................................................................... 5
1.6 Asumsi Dasar........................................................................................ 5
1.7 Sistematika Penulisan............................................................................ 6
BAB II KAJIAN PUSTAKA
2.1 Definisi Perawatan ............................................................................ 8
Institut Teknologi Adhi Tama Surabaya - ITATS 94

Skripsi
2.2 Tujuan Perawatan............................................................................... 8
2.3 Perawatan Pencegahan (Preventive Maintenence) ........................... 9
2.4 Kegiatan Pemeliharaan ................................................................... 12
2.5 Keuntungan Pemeliharaan Terencanan ........................................... 13
2.6 Masalah Efisiensi Dalam Pemeliharaan........................................... 14
2.7 Markov Chain.................................................................................. 17
2.8 Tahapan-Tahapan Markov Chain.................................................... 18
2.9 Syarat Dalam Analisa Markov Chain.............................................. 21
2.10 Klasifikasi Kondisi Kerusakan........................................................ 21
2.11 Keadaan Probabilitas Transisi.......................................................... 23
2.12 Menentukan Probabilitas Awal........................................................ 26
2.13 Menentukan Probabilitas n- langkah............................................... 28
2.14 Menghitung Probabilitas Transisi Perawatan Usulan...................... 29
2.15 Menentukan Matriks Probabilitas Transisi Kerusakan Mesin......... 30
2.16 Kelemahan dan Kelebihan Markov Chain....................................... 30
2.17 Menentukan Biaya Rata-Rata Perawatan......................................... 31
2.18 Biaya PM (Preventive Maintenence) dan CM (Corrective
Maintenence) Perusahaan.................................................................... 31
Maintenence) Usulan ......................................................................... 32
2.20 Perencanan Penjadwalan PM (Preventive Maintenence) Tahun 2018
dan 2019 Mesin Mill 303 Berdasarkan Metode Markov Chain.......... 33
2.21 Kajian Pustaka................................................................................. 35

Skripsi
BAB III METODE PENELITIAN
3.1 Tahap Indentifikasi Masalah .............................................................. 37
3.1.1 Perumusan Masalah ................................................................. 38
3.1.2 Penentuan Tujuan Penelitian ................................................... 38
3.1.3 Studi Literatur .......................................................................... 39
3.1.4 Studi Lapangan ........................................................................ 39
3.2 Tahap Pengumpulan Data....................................................................39
3.3 Tahap Pengolahan Data ...................................................................... 42
3.4 Tahap Analisa dan Pembahasan ......................................................... 44
3.5 Tahap Kesimpulan dan Saran ............................................................. 44
3.6 Flowchart Metodologi Penelitian ....................................................... 45
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA
4.1 Profil Perusahaan ............................................................................... 47
4.1.1 Gambaran Umum Perusahaan ................................................... 47
4.1.2 Sejarah Umum Perusahaan ....................................................... 47
4.1.3 Ruang Lingkup Bidang Usaha .................................................. 48
4.1.4 Lokasi Perusahaan ..................................................................... 48
4.1.5 Pemasaran ................................................................................. 49
4.1.6 Hasil Produksi ........................................................................... 49
4.1.7 Daerah Pemasaran ..................................................................... 50

Skripsi
4.1.8 Strategi Pemasaran .................................................................... 50
4.1.9 Hasil Produksi ........................................................................... 51
4.1.10 KapasitasProduksi ................................................................... 52
4.1.11 Uraian Proses Produksi ........................................................... 52
4.1.12 Mesin-Mesin dan Peralatan Produksi ...................................... 57
4.1.13 Sistem Perawatan Mesin dan Peralatan ................................... 61
4.1.14 Penggambaran Pola Aliran dan Pemindahan Bahan .............. 62
4.2 Data Waktu Pemeliharan .................................................................... 63
4.3 Data Downtime ................................................................................... 64
4.4 Data Perawatan dan Biaya PM (Preventive Maintenence) dan CM
(Corrective Maintenence)..................................................................... 65
4.5 Data Kerusakan Mesin Selama 2 Tahun (Perusahaan dan Usulan).... 66
4.6 Data Transisi Status Mesin.................................................................. 76
4.7 Menentukan Probabilitas Awal........................................................... 79
4.8 Menentukan Probabilitas n- Langkah................................................. 80
4.9 Menghitung Probabilitas Transisi Perawatan Usulan......................... 81
4.10 Menentukan Matriks Probabilitas Transisi Kerusakan Mesin.......... 82
4.11 Menentukan Biaya Rata-Rata Perawatan.......................................... 83
Maintenence) Perusahaan.......................................................................... 84
Maintenence) Usulan................................................................................ 85
4.14 Perencanan Penjadwalan PM (Preventive Maintenence) Tahun 2018

Skripsi
dan 2019 Mesin Mill 303 Berdasarkan Metode Markov Chain......... 85
BAB V ANALISA DAN PEMBAHASAN
5.1 Hail Perhitungan Biaya PM (Preventive Maintenence) dan CM
(Corrective Maintenence) Usulan...................................................... 89
5.2 Analisa Hasil...................................................................................... 90
BAB VI SIMPULAN DAN SARAN
6.1 Kesimpulan ........................................................................................ 94
6.2 Saran ................................................................................................... 95
DAFTAR PUSTAKA .......................................................................................... 96
LAMPIRAN ......................................................................................................... 97

Skripsi
DAFTAR TABEL
Halaman
Tabel 2.1 Status dan Kondisi Kerusakan .................................................................. 22
Tabel 2.2 Probabilitas Transisi ............................................................................ 24
Tabel 2.3 Probabilitas Kerusakan ........................................................................ 26
Tabel 2.4 probabilitas awal .................................................................................. 27
Tabel 2.5 Hasil Probabilitas Status Awal ............................................................. 27
Tabel 2.6 Probabilitas Transisi n – langkah ......................................................... 28
Tabel 2.7 Hasil Probabilitas n – langkah ............................................................. 29
Tabel 2.8 Probabilitas Transisi Perawatan Usulan ............................................... 30
Tabel 2.9 Matrik Probabilitas Transisi Kerusakan ............................................... 31
Tabel 2.10 Total Waktu dan Biaya PM Tahun 2018 dan 2019 ............................ 34
Tabel 2.11 Total Waktu dan Biaya PM Setiap 1 Kali Perawatan ........................ 34
Tabel 2.12 Periode waktu PM per1 Tahun .......................................................... 34
Tabel 2.13 Kajian Pustaka Penelitian ................................................................... 35
Tabel 4.1 Spesifikasi Produk Pipa Unit 3 ............................................................ 48
Tabel 4.2 Data Waktu Pemeliharan Dalam Perusahaan ........................................ 64
Tabel 4.3 Kode kerusakan mesin mill .................................................................. 65
Tabel 4.4 Pengelompokkan Data Kerusakan PM-CM Mesin Mill 303
Berdasarkan Downtime dan Tot. Biaya Maintenance Selama 2 Tahun
(perusahaan) ......................................................................................... 66
Skripsi
Tabel 4.5 Waktu pemeliharaan PM (Preventive Maintenance) dan CM (Corrective
Maintenance) usulan ............................................................................ 70
Tabel 4.6 Klasifikasi Kerusakan Mesin Mill 303 ................................................ 75
Tabel 4.7 probabilitas transisi Kegiatan Maintenance Mesin Mill 303 Tahun
(2016 dan 2017) Dari Perusahaan dan yang Diusulkan ...................... 76
Tabel 4.8 Hasil Probabilitas Status Awal ............................................................. 79
Tabel 4.9 Hasil probabilitas n – langkah .............................................................. 80
Tabel 4.10 Probabilitas Transisi Perawatan Usulan ............................................. 81
Tabel 4.11 Matrik Probabilitas Transisi Kerusakan ............................................. 83
Tabel 4.12 Total Waktu dan Biaya PM Tahun 2017 dan 2018 ............................ 86
Tabel 4.13 Total Waktu dan Biaya PM Setiap 1 Kali Perawatan ........................ 87
Tabel 4.14 Periode Waktu PM per 1 Tahun ......................................................... 88
Tabel 5.1 Selisih Biaya PM (Preventive Maintenance) dan CM (Corrective
Maintenance) perusahaan dan usulan ............................................... 89
Tabel 5.2 Biaya PM dan CM Perusahaan ............................................................ 90
Tabel 5.3 Biaya PM dan CM Usulan ................................................................... 91
Tabel 5.4 Total Waktu dan Biaya PM Tahun 2018 dan 2019 .............................. 91
Tabel 5.5 Total Waktu dan Biaya PM Setiap 1 Kali Perawatan .......................... 92
Tabel 5.6 Periode Waktu PM per 1 Tahun ........................................................... 93

Skripsi
DAFTAR GAMBAR
Gambar 2.1 Peristiwa dalam Markov Chain ....................................................... 18
Gambar 2.2 Skematis Himpunan Tertutup (Close Set) ........................................ 25
Gambar 3.1 Flowchart Metode Penelitian ........................................................... 45
Gambar 4.1 Pipa Baja Hitam (Black Pipe) .......................................................... 50
Gambar 4.2 Pipa Baja Lapis Seng (Galvanized Pipe) ......................................... 50
Gambar 4.3 Slitter 302 ......................................................................................... 58
Gambar 4.4 Mill 303 ............................................................................................ 59
Gambar 4.5 Tube Mill 301 – Accumulator ........................................................... 60
Gambar 4.6 Tube Mill 301 – Welding Machine ................................................... 60
Gambar 4.7 Tube Mill 301 – Cold Saw ................................................................ 61
Gambar 4.8 Vektor Transisi Diagram ................................................................. 78

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Skripsi

Jurusan Teknik Industri

1.1 Latar Belakang 1

1.3 Tujuan Penelitian ................................................................................. 4

1.4 Manfaat Penelitian ............................................................................... 4

1.5 Batasan Masalah ................................................................................... 5

1.6 Asumsi Dasar........................................................................................ 5

1.7 Sistematika Penulisan............................................................................ 6

BAB II KAJIAN PUSTAKA

2.1 Definisi Perawatan ............................................................................ 8

Institut Teknologi Adhi Tama Surabaya - ITATS 94

2.2 Tujuan Perawatan............................................................................... 8

2.3 Perawatan Pencegahan (Preventive Maintenence) ........................... 9

2.4 Kegiatan Pemeliharaan ................................................................... 12

2.5 Keuntungan Pemeliharaan Terencanan ........................................... 13

2.6 Masalah Efisiensi Dalam Pemeliharaan........................................... 14

2.7 Markov Chain.................................................................................. 17

2.8 Tahapan-Tahapan Markov Chain.................................................... 18

2.9 Syarat Dalam Analisa Markov Chain.............................................. 21

2.10 Klasifikasi Kondisi Kerusakan........................................................ 21

2.11 Keadaan Probabilitas Transisi.......................................................... 23

2.12 Menentukan Probabilitas Awal........................................................ 26

2.13 Menentukan Probabilitas n- langkah............................................... 28

2.14 Menghitung Probabilitas Transisi Perawatan Usulan...................... 29

2.15 Menentukan Matriks Probabilitas Transisi Kerusakan Mesin......... 30

2.16 Kelemahan dan Kelebihan Markov Chain....................................... 30

2.17 Menentukan Biaya Rata-Rata Perawatan......................................... 31

2.18 Biaya PM (Preventive Maintenence) dan CM (Corrective

2.19 Biaya PM (Preventive Maintenence) dan CM (Corrective

Maintenence) Usulan ......................................................................... 32

2.20 Perencanan Penjadwalan PM (Preventive Maintenence) Tahun 2018

dan 2019 Mesin Mill 303 Berdasarkan Metode Markov Chain.......... 33

2.21 Kajian Pustaka................................................................................. 35

Institut Teknologi Adhi Tama Surabaya - ITATS 95

BAB III METODE PENELITIAN

3.1 Tahap Indentifikasi Masalah .............................................................. 37

3.1.1 Perumusan Masalah ................................................................. 38

3.1.2 Penentuan Tujuan Penelitian ................................................... 38

3.1.3 Studi Literatur .......................................................................... 39

3.1.4 Studi Lapangan ........................................................................ 39

3.2 Tahap Pengumpulan Data....................................................................39

3.3 Tahap Pengolahan Data ...................................................................... 42

3.4 Tahap Analisa dan Pembahasan ......................................................... 44

3.5 Tahap Kesimpulan dan Saran ............................................................. 44

3.6 Flowchart Metodologi Penelitian ....................................................... 45

BAB IV PENGUMPULAN DAN PENGOLAHAN DATA

4.1 Profil Perusahaan ............................................................................... 47

4.1.1 Gambaran Umum Perusahaan ................................................... 47

4.1.2 Sejarah Umum Perusahaan ....................................................... 47

4.1.3 Ruang Lingkup Bidang Usaha .................................................. 48

4.1.4 Lokasi Perusahaan ..................................................................... 48

4.1.5 Pemasaran ................................................................................. 49

4.1.6 Hasil Produksi ........................................................................... 49

4.1.7 Daerah Pemasaran ..................................................................... 50

Institut Teknologi Adhi Tama Surabaya - ITATS 96

4.1.8 Strategi Pemasaran .................................................................... 50

4.1.9 Hasil Produksi ........................................................................... 51

4.1.10 KapasitasProduksi ................................................................... 52

4.1.11 Uraian Proses Produksi ........................................................... 52

4.1.12 Mesin-Mesin dan Peralatan Produksi ...................................... 57

4.1.13 Sistem Perawatan Mesin dan Peralatan ................................... 61

4.1.14 Penggambaran Pola Aliran dan Pemindahan Bahan .............. 62

4.2 Data Waktu Pemeliharan .................................................................... 63