TUGAS AKHIR. Oleh : NAMA : RENI YULIANTI NIM : NIRM :

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 Ir. Dyah Retno P, MT

DAFTAR ISI Halaman HALAMAN JUDUL... LEMBAR PERSETUJUAN... BERITA ACARA BIMBINGAN TUGAS AKHIR... BERITA ACARA UJIAN TUGAS AKHIR... i ii iii iv ABSTRAKSI... v SURAT KETERANGAN PENELITIAN... vi KATA PENGANTAR... DAFTAR ISI... DAFTAR TABEL... DAFTAR GAMBAR... DAFTAR LAMPIRAN... vii ix xi xiii 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. Analisa Biaya... 22

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 5.4. Analisa Biaya... 98

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 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +-------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 +---------------------- 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 Siklus (1) pemeliharaan preventif (n) Bln (2) Perkiraan kerusakan dalam siklus PM, Bi (3) Jumlah ratarata kerusakan/bln (kol 2/kol 1) Tabel 5-5 Periode Pemeliharaan Pencegahan (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 masingmasing 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 / C PM ) = Rp. 671.900 Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 14.326.500 Periode pemeliharaan preventif biaya minimum adalah setiap satu bulan sekali

2. Mesin Putaran Conti Tabel 5-6 Periode Pemeliharaan Pencegahan Siklus (1) pemeliharaa n preventif (n) Bln (2) Perkiraan kerusakan dalam siklus PM, Bi (3) Jumlah ratarata 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 masingmasing 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 / C PM ) = Rp. 679.100 Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 24.571.593,75 Periode pemeliharaan preventif biaya minimum adalah setiap satu bulan sekali

3. Mesin Bucket Elevator Siklus (1) pemeliharaan preventif (n) Bln (2) Perkiraan kerusakan dalam siklus PM, Bi (3) Jumlah ratarata kerusakan/bln (kol 2/kol 1) Tabel 5-7 Periode Pemeliharaan Pencegahan (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 masingmasing 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 / C PM ) = Rp. 307.500 Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 52.954.122,7 Periode pemeliharaan preventif biaya minimum adalah setiap satu bulan sekali

4. Mesin Vibrating Screen Tabel 5-8 Periode Pemeliharaan Pencegahan Siklus (1) pemelihar aan preventif (n) Bln Perkiraan (2) 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 masingmasing 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 / C PM ) = Rp. 307.500 Biaya perawatan perbaikan (Cost repair / Cr) = Rp. 32.373.000 Periode pemeliharaan preventif biaya minimum adalah setiap satu bulan sekali