Perencanaan Strategi Dan Kebijakan Perawatan Mesin Granulasi Berdasarkan Evaluasi Nilai Efektivitas Peralatan Produksi

PERENCANAAN STRATEGI DAN KEBIJAKAN PERAWATAN MESIN GRANULASI BERDASARKAN EVALUASI NILAI EFEKTIVITAS PERALATAN PRODUKSI
Penulis : Aldi Sebastian, ARIF RAHMAN & Remba Yanuar Efranto

Abstrak : Perusahaan penghasil pupuk organik non sintetis menggunakan mesin granulasi dalam sistem produksinya. Mesin granulasi merupakan peralatan pencampur bahan baku berupa kompos dan cairan kimia organik untuk menghasilkan pupuk granul. Mesin granulasi terdiri dari tiga alat, yaitu pan granulator, rotary dryer dan rotary screen. Strategi dan kebijakan perawatan yang sesuai pada mesin granulasi dapat mengurangi losses dan meningkatkan efektivitas peralatan. Penelitian ini mengukur efektivitas mesin granulasi mempergunakan Overall Equipment Effectiveness (OEE) yang didapatkan dari perkalian availability rate, performance rate dan quality rate. Hasil penelitian ini menunjukan bahwa rata-rata nilai OEE pada pan granulator sebesar 67,49%, rotary dryer sebesar 67,65% dan rotary screen sebesar 66,42%. Nilai OEE tersebut masih di bawah 85%, standar pada Japan Institute of Plant Maintenance (JIPM). Dengan metode Failure Mode and Effect Analysis (FMEA) diprioritaskan pada kegagalan tiga komponen, yaitu kegagalan Dust Collector, kegagalan Unit parabola dan kegagalan Drive Line Assembly. Rekomendasi perbaikan berdasarkan konsep Total Productive Maintenance (TPM) yang diusulkan terdiri dari 2 Preventive Maintenance, 3 Corrective Maintenance dan 5 Predictive Maintenance. Preventive Maintenance dilakukan untuk mencegah korosi pada cyclone dan korosi pada pan. Corrective Maintenance dilakukan untuk penanganan Invalid Design, Alas Pan pecah dan Sambungan Las Lepas. Predictive Maintenance dilakukan untuk penanganan penyumbatan unit cyclone, sprayer tersumbat, fabric filter sobek, bearing aus dan rantai error.
Kata kunci : Mesin Granulasi, Overall Effectiveness Equipment (OEE), Six Big Losses, Failure Mode and Effect Analysis (FMEA), Total Productive Maintenance (TPM).

STRATEGIC PLANNING AND MAINTENANCE POLICY OF GRANULATING MACHINE UNDER EVALUATION OF OVERALL EQUIPMENT EFFECTIVENESS

Abstract : A non-synthetic organic fertilizer producer uses granulating machines in the production system. The granulating machines are material mixing equipment consisting of compost and organic chemical liquid to produce granule fertilizer. The granulating machines consist of three equipments, namely pan granulator, rotary dryer and rotary screen. The appropriate maintenance strategies and policies on granulating machines can reduce losses and increase equipment effectiveness. This study measures the effectiveness of granulating machines using Overall Equipment Effectiveness (OEE) which obtained from the multiplication of availability rate, performance rate and quality rate. The results shows that the average value of OEE in granulator pan of 67.49%, rotary dryer of 67.65% and rotary screen of 66.42%. The OEE values are below 85%, standard of Japan Institute of Plant Maintenance (JIPM). The FMEA prioritizes on the failure of three components, namely Dust Collector failure, Parabolic Unit failure and Drive Line Assembly failure. It recommends improvements based on Total Productive Maintenance (TPM) concept consist of 2 Preventive Maintenance, 3 Corrective Maintenance and 5 Predictive Maintenance. Preventive Maintenance are preventing for corrosion of cyclone and corrosion of pan. Corrective Maintenance are repairing for Invalid Design, Broken Pan Beds and Broken Welded Connections. Predictive Maintenance are anticipating for blocked cyclone unit, clogged sprayer, torn fabric filter, worn bearings and error chain.
Keywords : Granulating Machines, Overall Effectiveness Equipment (OEE), Six Big Losses, Failure Mode and Effect Analysis (FMEA), Total Productive Maintenance (TPM).

Artikel dipublikasikan dalam Jurnal Rekayasa dan Manajemen Sistem Industri Vol 4 No 3 thn 2016, pp
Artikel dapat diperiksa di situs jrmsi
Artikel dapat didownload pdf

This entry was posted in My Students and tagged , , , , . Bookmark the permalink.