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 MESIN DENGAN
MENGGUNAKAN METODE 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 Mas’udin, ST
Mengetahui, Ketua Jurusan Industri
DAFTAR ISI
Halaman
HALAMAN JUDUL... i
LEMBAR PERSETUJUAN... ii
BERITA ACARA BIMBINGAN TUGAS AKHIR... iii
BERITA ACARA UJIAN TUGAS AKHIR... iv
ABSTRAKSI ... v
SURAT KETERANGAN PENELITIAN... vi
KATA PENGANTAR... vii
DAFTAR ISI... ix
DAFTAR TABEL ... xi
DAFTAR GAMBAR ... xiii
DAFTAR LAMPIRAN... xiv
BAB I PENDAHULUAN 1.1. Latar belakang... 1 1.2. Perumusan Masalah... 2 1.3. Tujuan Penelitian... 2 1.4. Manfaat Penelitian... 3 1.5. Batasan Masalah... 3 1.6. Asumsi – asumsi ... .. 4 1.7. Sistematika Penulisan ... ... 5
BAB II LANDASAN TEORI 2.1. Sistem Perawatan ... 7
2.1.1. Pengertian Dan Tujuan Perawatan... 7
2.1.2. Jenis-jenis Perawatan ... 9
2.1.3. Model Peraawatan Ideal... 11
2.1.4. Kebijaksanaan Perawatan ... 12
2.2. Klasifikasi Kondisi Kerusakan... 13
2.3. Proses Markov Chain ... 14
2.3.1. Penaksiran Parameter Markov... 17
2.3.2. Kegunaan Probabilitas dan Keputusan Markov... 19
2.4.1. Biaya Penyelenggaraan Perawatan Pencegahan... 23
2.4.2. Biaya Korektif... 23
2.4.3. Ekspektasi Biaya... 24
2.5. Perhitungan Periode Pemeliharaan Mesin yang Optimal... 24
BAB III METODOLOGI PENELITIAN 3.1. Survey Perusahaan... 25
3.2. Identifikasi Masalah dan Penentuan Tujuan... 26
3.3. Study Literatur... 28
3.4. Pengumpulan Data ... 28
3.5. Pengolahan Data... 31
3.6 Perencanaan Perawatan Mesin dengan Metode Markov Chain... 37
3.7. Analisa Hasil... 37
3.8. Kesimpulan dan Saran ... 37
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA 4.1. Pengumpulan ... 38
4.1.1. Data Jenis Mesin ... 38
4.1.2. Data Mesin yang Mengalami Transisi Staatus Tiap Item... 38
4.1.3. Data Mesin yang Berada pada Status Baaik, Kerusakan Ringan,Sedang dan Berat... 40
4.1.4. Data Waktu Pemeliharaan Pencegahan... 42
4.1.5. Data Waktu Rata-rata Kerusakan Mesin ... 43
4.1.6. Data Biaya Downtime... 45
4.2. Jenis-Jenis Perawatan yang Dilakukan Perusahaan... 47
4.2.1. Jenis-jenis Perawatan Pencegahan ... 47
4.2.2. Jenis-jenis Perawatan Perbaikan... 48
4.3. Pengolahan Data... 49
4.3.1. Perhitungan Probabilitas Status Masing-masing Item... 49
4.3.2. Perhitungan Probabilitas Status untuk Perencanaan Perawatan Usulan ... 55
4.3.3. Perhitungan Periode Pemeliharaan Mesin Optimal ... 82
BAB V ANALISA DATA 5.1. Probabilitas Transisi... 91
5.2. Matriks Transisi Untuk Perencanaan Perawatan Usulan ... 92
5.3. Probabilitas Status dalam Keadaan Steady State ... 96
5.5. Analisa Periode Pemeliharaan Pencegahan... 105 5.6. Analisa Hasil... 109 BAB VI KESIMPULAN DAN SARAN
6.1. Kesimpulan... 111 6.2. Saran ... 112 DAFTAR PUSTAKA
LAMPIRAN
Halaman Gambar 2.1 Skematis Himpunan Tertutup (Close Set)... 21 Gambar 3.1 Metodologi Pemecahan Masalah... 27
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 5.7 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
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
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 kore ktif 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 kore ktif 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. Perencanaan perawatan usulan mesin Bucket Elevator
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 ¦[.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. Perencanaan perawatan usulan mesin Vibrating Screen
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 ¦[0.8055 ][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 ¦ M ¦ ¦ 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 ¦ State ¦ Recurrence ¦ State ¦ State ¦ Recurrence ¦ ¦ Name ¦Probability ¦ Time ¦ Name ¦Probability ¦ Time ¦ +---+---+---+---+---+---¦ ¦ S1 ¦ .6334749 ¦ M ¦ S3 ¦ .087007 ¦ M ¦ ¦ S2 ¦ .1772188 ¦ M ¦ S4 ¦ .1013933 ¦ 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 13:43:36 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. Mesin Putaran Conti
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 13:48:14 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. Mesin Bucket elevator
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 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. Mesin Vibrating Screen
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 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) Siklus pemeliharaan preventif (n) Bln (2) Perkiraan kerusakan dalam siklus PM, Bi (3) Jumlah rata-rata kerusakan/bln (kol 2/kol 1) (4) Perkiraan biaya kerusakan bulanan (kol 3 x Rp. 14.326.500) (5) Perkiraan biaya PM bulanan (Rp.671.900x7)/kol 1 (6) Perkiraan biaya bulanan masing-masing siklus PM (kol 4 + kol 5) 1 2.8 2.8 40114200 4703300 44817500 2 6.72 3.36 48137040 2351650 50488690 3 12.21 4.07 58308855 1567767 59876622 4 19.89 4.9725 71238521 1175825 72414346 5 27.96 5.592 80113788 940660 81054448 6 44.63 7.438333 1.07E+08 783883.3 1.07E+08
Biaya perawatan pencegahan (Cost Preventive Maintenance / CP M) = Rp. 671.900
Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 14.326.500
2. Mesin Putaran Conti
Tabel 5-6
Periode Pemeliharaan Pencegahan
(1) Siklus pemeliharaa n preventif (n) Bln (2) Perkiraan kerusakan dalam siklus PM, Bi (3) Jumlah rata-rata kerusakan/bln (kol 2/kol 1) (4) Perkiraan biaya kerusakan bulanan (kol 3xRp. 24.571.593,75) (5) Perkiraan biaya PM bulanan (Rp.679.100x7)/kol 1 (6) Perkiraan biaya bulanan masing-masing siklus PM (kol 4 + kol 5) 1 2.2 2.2 54057506 7470100 61527606* 2 4.84 2.42 59463257 3735050 63198307 3 8.23 2.743333 67408072 2490033 69898106 4 15.81 3.9525 97119224 1867525 98986749 5 17.22 3.444 84624569 1494020 86118589 6 22.86 3.81 93617772 1245017 94862789
Biaya perawatan pencegahan (Cost Preventive Maintenance / CP M) = Rp. 679.100
Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 24.571.593,75
3. Mesin Bucket Elevator
Tabel 5-7
Periode Pemeliharaan Pencegahan (1) Siklus pemeliharaan preventif (n) Bln (2) Perkiraan kerusakan dalam siklus PM, Bi (3) Jumlah rata-rata kerusakan/bln (kol 2/kol 1) (4) Perkiraan biaya kerusakan bulanan (kol 3 x Rp. 52.954.122,7) (5) perkiraan biaya PM bulanan (Rp.307.500 x 7) /kol 1 (6) Perkiraan biaya bulanan masing-masing siklus PM (kol 4 + kol 5) 1 0,9 0,9 47658710,43 922500 48581210,43 * 2 2,07 1,035 54807516,99 461250 55268766,99 3 3,59 1,196667 63368433,5 307500 63675933,5 4 5,57 1,3925 73738615,86 230625 73969240,86 5 8,14 1,628 86209311,76 184500 86393811,76 6 6,98 1,163333 61603296,07 153750 61757046,07 Biaya perawatan pencegahan (Cost Preventive Maintenance / CP M) = Rp. 307.500
Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 52.954.122,7
4. Mesin Vibrating Screen
Tabel 5-8
Periode Pemeliharaan Pencegahan
(1) Siklus pemelihar aan preventif (n) Bln (2) Perkiraan kerusakan dalam siklus PM, Bi (3) Jumlah rata-rata kerusakan/bln (kol 2/kol 1) (4) Perkiraan biaya kerusakan bulanan (kol 3 x Rp. 32.373.000) (5) perkiraan biaya PM bulanan (Rp.307.500x7)/kol1 (6) Perkiraan biaya bulanan masing-masing siklus PM (kol 4 + kol 5) 1 3,5 3,5 50142750 4703300 54846050* 2 8,75 4,375 62678437,5 2351650 65030087,5 3 16,63 5,543333 79416565 1567767 80984331,67 4 28,44 7,11 101861415 1175825 103037240 5 46,16 9,232 132262248 940660 133202908 6 72,74 12,12333 173684935 783883,3 174468818,3 Biaya perawatan pencegahan (Cost Preventive Maintenance / CP M) = Rp. 307.500
Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 32.373.000