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TUGAS AKHIR
ANALISA TEAR DOWN REPORT DIESEL ENGINE
MODEL DE12TIA MENGGUNAKAN METODE SEVEN
TOOLS (PT KOBEXINDO TRACTORS TBK)
Diajukan Sebagai Syarat Untuk Mencapai Gelar Sarjana Teknik
Jurusan Teknik Mesin Fakultas Teknik
Universitas Muhammadiyah Surakarta
Disusun oleh :
MUSTOFA FARIS IZZUDDIN
NIM : D200140218
JURUSAN TEKNIK MESIN FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2018
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MOTTO
“Man Lam Yadzuq Murrot Ta’allumi Sa’atan, Tajarro’a Dzullal Jahli Thulal
Hayaatihi”
“Barang siapa belum pernah merasakan pahitnya (payahnya) menuntut ilmu
walau sesaat, Ia akan menelan hinanya kebodohan sepanjang hidupnya”
“Barangsiapa menyia-nyiakan waktu menuntut ilmu di masa mudanya, maka
bertakbirlah empat kali atas kematiannya.”
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ABSTRAKSI
Tear Down Report adalah format laporan yang diterapkan oleh PT
kobexindo Tractors untuk pekerjaan corrective maintenance & overhaul engine.
Di dalamnya memuat analisa kerusakan dan recommended part engine replace.
Dari hasil tear down report tersebut dilakukan analisa lanjutan menggunakan
metode seven tools dengan tujuan analisa untuk mengetahui jenis (NG) failure dan
cause of failure yang dominan terjadi. Selain itu, pada beberapa bagian dari
analisa tersebut juga memuat informasi mengenai komponen diesel engine yang
banyak terjadi kasus uncomplete, miss dan damage pada saat engine beroperasi.
Seven Tools adalah tujuh alat kendali mutu yang banyak digunakan untuk
analisa statistik di dalam dunia teknik industri. Penerapan metode seven tools
dapat digunakan pula di dalam dunia pendidikan, manajemen, ekonomi bisnis,
psikologi dll. Tujuannya adalah untuk perbaikan dan pengendalian kualitas .
Tujuh alat kendali mutu tersebut meliputi check sheet, stratifikasi, fish bone
diagram, pareto diagram, histogram, scatter diagram, dan control chart.
Hasilnya, dari analisa seven tools terhadap tear down report 24 engine
model DE12TIA yang dilakukan corrective maintenance dan overhaul, terdapat
16 jenis (NG) failure dengan angka worn (keausan) menjadi yang paling tinggi
yaitu sebanyak 70 kasus. Sedangkan untuk cause of failure terdapat 22 kasus
dengan bad lubricating menjadi yang paling tinggi sebanyak 86 kasus. Kemudian
Analisa scatter diagram untuk kasus prioritas yaitu worn sebagai variabel Y dan
bad lubricating sebagai variabel X menghasilkan korelasi posistif dengan nilai
korelasi r > 0 yaitu 0,95, ini berarti semakin tinggi angka bad lubricating maka
akan semakin tinggi pula angka Worn (keausan).
Kata Kunci :Tear Down Report, Failure, Cause Of Failure, Seven tools.
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ABSTRACT
Tear Down Report is a report format applied by PT Kobexindo Tractors
for corrective maintenance & overhaul engine work. In it contains damage
analysis and recommended replace engine parts. From the results of the tear
down report, further analysis is performed using the seven tools method with the
aim of analysis to determine the type of (NG) failure and the dominant cause of
failure. In addition, in some parts of the analysis also contains information about
diesel engine components that occur in many cases uncomplete, miss and damage
when the engine is operating.
Seven Tools are seven quality control tools that are widely used for
statistical analysis in the world of industrial engineering. The application of the
seven tools method can also be used in the world of education, management,
business economics, psychology etc. The aim is to improve and control quality.
The seven quality control tools include check sheets, stratification, fish bone
diagrams, pareto diagrams, histograms, scatter diagrams, and control charts.
As a result, from the seven tools analysis of the 24 engine DE12TIA model
tear down report which is corrective maintenance and overhaul, there were 16
types (NG) failure with the highest wear rate (70 cases). While for cause of failure
there were 22 cases with bad lubricating being the highest as many as 86 cases.
Then the scatter diagram analysis for priority cases is worn as variable Y and bad
lubricating as the X variable produces a positive correlation with the correlation
value r> 0 which is 0.95, this means that the higher the number of bad lubricating
the higher the number of Worn (wear).
Keywords: Tear Down Report, Failure, Cause Of Failure, Seven tools.
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KATA PENGANTAR
Assalamualaikum Wr,Wb
Syukur Alhamdulillah penulis panjatkan kehadirat Allah SWT atas berkah
dan rahmat-nya sehingga penyusunan laporan ini dapat terselesaikan. Tugas akhir
yang berjudul “ANALISA TEAR DOWN REPORT ENGINE DIESEL MODEL
DE12TIA MENGGUNAKAN METODE SEVEN TOOLS (PT KOBEXINDO
TRACTORS TBK)” dapat terselesaikan atas dukungan dari berbagai pihak.
Untuk itu, penulis pada kesempatan ini dengan ketulusan dan keiklasan hati yang
mendalam menyampaikan rasa terima kasih dan penghargaan besar kepada :
1. Bapak Ir. H Subroto, M.T selaku Ketua Jurusan Teknik Mesin Universitas
Muhammadiyah Surakarta.
2. Bapak Dr. Suranto selaku Direktur Sekolah Vokasi Universitas
Muhammadiyah Surakarta.
3. Bapak Amin Sulistyanto, S.T., M.T. selaku Dosen Pembimbing yang telah
banyak memberikan banyak ilmu, pengarahan, dan bimbingan kepada
penulis dalam menyelesaikan tugas ini.
4. Keluarga tercinta, bapak, ibu, dan adik yang selalu memberikan dukungan
dan doanya.
5. Teman-teman Teknik Mesin angkatan 2014 yang banyak memberi
semangat dan kebersamaannya.
6. Management PT Kobexindo Tractors Tbk, atas kesempatan yang
diberikan kepada penulis untuk menyelenggarakan penilitian ini.
7. Semua pihak yang telah membantu dalam penelitian dan penyusunan
laporan tugas akhir ini.
Didalam penyusunan/pembuatan laporan ini masih jauh dari kata
sempurna. Untuk itu, kritikan maupun saran yang bersifat membangun dengan
harapan pembuatan laporan selanjutnya dapat lebih baik. Semoga laporan ini
dapat berguna dan memberikan manfaat kedepannya.
Wassalamu’ailaikum Wr.Wb
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DAFTAR GAMBAR
Gambar 2. 1 Kurva Performance Engine ........................................ ................................6
Gambar 2.2 Letak Posisi Engine Number ..................................... ..................................6
Gambar 2.3 Engine Sectional View(Longitudinal) ............................. ............................7
Gambar 2.4 Engine Sectional View (Cross) ....................................... ........................... 8
Gambar 2.5 Engine Assembly Views ................................................... ......................... 9
Gambar 2.6 Engine View (Top) ......................................................... ...........................10
Gambar 2.7 Engine Mounting .............................................................. .........................10
Gambar 2.8 Cylinder Head .............................................................. .............................12
Gambar 2.9 Gambar Cylinder Head Cover ........................................ ...........................13
Gambar 2.10 Gambar Cylinder Block ................................................ ..........................15
Gambar 2.11 Gambar Pressure Gauge ...........................................................................16
Gambar 2.12 Driving System .........................................................................................21
Gambar 2.13 Fly Wheel Housing ....................................................... ...........................22
Gambar 2.14 Timing System ........................................................... .............................24
Gambar 2.15 Timing Gear Case ....................................................... .............................26
Gambar 2.16 Gambaran Umum Fuel System .................................... ...........................27
Gambar 2.17 Fuel System Engien DE12TIA ....................................... .........................28
Gambar 2.18 Fuel Pipe pada Fuel System Engine DE12TIA ............. ..........................30
Gambar 2.19 Fuel Filter pada Fuel System Engine DE12TIA ......... ............................31
Gambar 2.20 Injection Nozzle pada Fuel System Engine DE12TIA .... ........................31
Gambar 2.21 Fuel Pipe pada Fuel System Engine DE12TIA ................... ....................32
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Gambar 2.22 Injection Pump pada Fuel System Engine DE12TIA ........... ...................32
Gambar 2.23Injection Pump Drive ......................................................... ......................33
Gambar 2.24 Injection Pump Mounting .......................................................... ............. 34
Gambar 2.25 Engine Control ........................................................................... .............35
Gambar 2.26 Exhaust Manifold pada Exhaust System Engine DE12TIA ...... ............. 36
Gambar 2.27 Intake Manifold pada Intake System Engine DE12TIA ..... ...................37
Gambar 2.28 Intake Stake ........................................................................... ......... ....... 38
Gambar 2.29 Turbo Charger pada Engine DE12TIA .................................. .................38
Gambar 2.30 Breather................................................................................... ............... 40
Gambar 2.31 Gambaran Umum Lubrication System ................................. .................. 41
Gambar 2.32 Oil Pump pada Engine DE12TIA ........................................... ............... 42
Gambar 2.33 Oil Filter pada Lubricating System Engine DE12TIA ............ ............... 43
Gambar 2.34 Oil Pan pada Lubricating System Engine DE12TIA ............ ..................44
Gambar 2.35 Gambaran Umum Cooling system Engine DE12TIA ............ ................ 46
Gambar 2.36 Thermostat pada Engine DE12TIA ........................................ ................ 47
Gambar 2.37 Sketsa Mekanisme Thermostat ................................................ ............... 47
Gambar 2.38 Cooling Water Pipe Pada Cooling System Engine DE12TIA . ...............48
Gambar 2.39 Water Pump pada Cooling System Engine DE12TIA ............. ...............50
Gambar 2.40 Oil Cooler pada Cooling System Engine DE12TIA ................. ..............51
Gambar 2.41 Cooling Fan pada Cooling System Engine DE12TIA ............. ...............52
Gambar 2.42 Starter pada Electric System Engine DE12TIA...................... ............... 54
Gambar 2.43 Alternator pada Engine DE12TIA ......................................... ................. 54
Gambar 2.44 Alternator Mounting Pada Alternator Engine DE12TIA .......... ............. 55
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Gambar 2.45 Electric Control Unit Pada Electrical System .................. ...................... 56
Gambar 2.46 Electric Ignition System pada Electrical System .............. ..................... 56
Gambar 2.47 Power Steering Pump ......................................................... .................... 57
Gambar 2.48Air Compressor ..................................................................... .................. 58
Gambar 2.49Air Conditioner ........................................................................... ............ 60
Gambar 2.50 Accessory Part Engine DE12TIA ............................................................62
Gambar 3.1 Sketsa Pola Histogram Distribusi Normal .................... ............................ 77
Gambar 3.2 Kurva Normal Distribution .............................................. .........................77
Gambar 3.3 Sketsa Pola Histogram Skewed Distribution ................... .........................78
Gambar 3.4 Sketsa Pola Histogram Bimodal Distribution ................. ..........................78
Gambar 3.5 Sketsa Pola Histogram Nilai Data Tersebar Rata ............. .........................79
Gambar 3.6 Jenis-Jenis Korelasi Antara Dua Variabel ......................... ........................80
Gambar 3.7 Contoh /Gambaran Umum Diagram Fish Bone ................ ....................... 83
Gambar 3.8 Contoh X Chart ................................................................... ......................86
Gambar 3.9 Flow Chart Overhaul & TDR Engine.................................... .................. 89
Gambar 4.1 Grafik Stratifikasi Failure Terhadap Masing Masing Engine ….........….. 98
Gambar 4.2 Diagram Fish Bone Analisa Damage Tear Down Report Engine….........101
Gambar 4.3Diagram Pareto Jenis Failure Tear Down Report Engine Pada
Analisa Damage Tear Down Report Engine DE12TIA .................. ............................104
Gambar 4.4 Diagram Pareto Cause Of Failure Pada Analisa Damage Tear
Down Report Engine DE12TIA ................................................ ..................................105
Gambar 4.5 Histogram Type Of Failure Pada Analisa Damage Tear Down
Report Engine DE12TIA .......................................................... .................................. 106
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Gambar 4.6 Histogram Cause Of Failure Pada Analisa Damage Tear Down
Report Engine DE12TIA ............................................................................. ............... 107
Gambar 4.7 Diagram Scatter Bad Lubricating Terhadap Worn (Keausan) ............... 108
Gambar 4.8 Diagram Scatter Fatique Terhadap Worn (Keausan)............. ..................110
Gambar 4.9 Diagram Scatter Fatique Terhadap NG Broken ……….........……..…... 111
Gambar 4.10 Grafik Peta Keseluruhan Failure Pada Analisa Damage Tear
Down Report Engine DE12TIA ............................................... ................... .. 113
Gambar 4.11 Grafik Peta Kendali Worn (Keausan) Pada Analisa Damage Tear
Down Report Engine DE12TIA ............................................... ..................... .115
Gambar 4.12 Grafik Peta Kendali NG Broken Pada Analisa Damage Tear
Down Report Engine DE12TIA ................................................ ......................117
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DAFTAR TABEL
Tabel 2.1 General Spesifications Engine DE12TIA ................................. ......................5
Tabel 2.2 Engine Performance Between DE12TI & DE12TIS / TIA ........ .................... 5
Tabel 2.3 Bagian Bagian Engine Mounting ................................................. ................ 10
Tabel 2.4 Bagian Bagian Cylinder Head ..................................................... ................. 12
Tabel 2.5 Bagian Bagian Cylinder Head Cover ....................................... .................... 13
Tabel 2.6 Bagian Bagian Cylinder Block ................................................ .....................15
Tabel 2.7 Bagian Bagian Pressure Gauge ................................................ .....................16
Tabel 2.8 Bagian Bagian Driving System ................................................. ................... 19
Tabel 2.9 Bagian Bagian Fly Wheel Housing ............................................. ................. 21
Tabel 2.10 Bagian Bagian Timing System .................................................... ...............24
Tabel 2.11 Bagian Bagian Timing Gear Case ........................................ .......................26
Tabel 2.12 Bagian Bagian Fuel System Engine DE12TIA ..................... ..................... 29
Tabel 2.13 Bagian Bagian Fuel Pipe pada Fuel System Engine DE12TIA ... .............. 30
Tabel 2.14 Bagian Bagian Fuel Filter pada Fuel System Engine DE12TIA ... .............31
Tabel 2.15 Bagian² Injection Nozzle pada Fuel System Engine DE12TIA ..... ........... 32
Tabel 2.16 Bagian² Fuel Pipe pada Fuel System Engine DE12TIA.............. ............... 32
Tabel 2.17 Bagian² Injection Pump pada Fuel System Engine DE12TIA ......... .......... 33
Tabel 2.18 Bagian Bagian Injection Pump Drive ...................................... ...................33
Tabel 2.19 Bagian Bagian Injection Pump Mounting ............................... ....................34
Tabel 2.20 Bagian Bagian Engine Control ................................................ ...................35
Tabel 2.21 Bagian² Exhaust Manifold pada Exhaust System .................. .....................36
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Tabel 2.22 Bagian² Intake Manifold pada Intake System ............................ ................ 37
Tabel 2.23 Bagian Bagian Intake Stake........................................................ ................ 38
Tabel 2.24 Bagian Bagian Turbo Charger pada Engine DE12TIA .............. ................39
Tabel 2.25 Bagian Bagian Breather .............................................................. ................39
Tabel 2.26 Recommended Oil ...................................................................... ................ 41
Tabel 2.27 Engine Oil Capacity ..................................................................... .............. 42
Tabel 2.28 Bagian Bagian Oil Pump Engine DE12TIA ................................. ..............42
Tabel 2.29 Bagian² Oil Filter pada Lubricating System Engine DE12TIA ...... ............43
Tabel 2.30 Bagian² Oil Pan pada Lubricating System Engine DE12TIA ....... ..............44
Tabel 2.31 Bagian Bagian Thermostat......................................................... ............…..47
Tabel 2.32 Thermostat Type ........................................................................ .................48
Tabel 2.33 Bagian² Cooling Water Pipe Pada Cooling System ............... .....................48
Tabel 2.34 Bagian² Water Pump pada Cooling System ............................. ...................50
Tabel 2.35 Bagian ² Oil Cooler pada Cooling System ................................. .................51
Tabel 2.36 Bagian² Cooling Fan pada Cooling System ............................. ...................53
Tabel 2.37 Coolant Volume……………………………................................................53
Tabel 2.38 Bagian² Starter pada Electric System ....................................... .................. 54
Tabel 2.39 Bagian² Alternator pada Engine DE12TIA ............................... ..................55
Tabel 2.40 Bagian² Alternator Mounting Pada Alternator .................... ....................... 55
Tabel 2.41 Bagian² Electric Control Unit Pada Electrical System ................. ..............56
Tabel 2.42 Bagian² Electric Ignition System pada Electrical System ........... ................57
Tabel 2.43 Bagian Bagian Power Steering Pump.......................................... ................58
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Tabel 2.45 Bagian Bagian Air Compressor .......................................... ........................59
Tabel 2.46 Bagian Bagian Air Conditioner ........................................... ........................61
Tabel 2.47 Bagian Bagian Accessory Part Engine DE12TIA ................ ...................... 61
Tabel 4.1 Data Engine RFU Selama Periode 2014 -2018 ......................... ................... 92
Tabel 4.2 Data Engine DE12TIA Periode 2014 – 2015 ............................. ................. 92
Tabel 4.3 Summary Uncomplete Komponen Tear Down Report Engine......... ........... 93
Tabel 4.4 Summary Miss Component ......................................... ................................. 95
Tabel4.5 Summary Damage Component ..................................... ................................ 96
Tabel 4.6 Stratifikasi Failure Terhadap Masing Masing Engine
DE12TIA 322536EC. ................................................................................. ...................98
Tabel 4.7 Stratifikasi Responsible Terhadap Cause Of Failure.................... ................ 99
Tabel 4.8 Sampel Tabel Analisa Damage pada Tear Down Report Engine….........…100
Tabel 4.9Data Hasil Perhitungan 10 Failure (NG) Terbesar Pada Analisa
Damage Tear Down Report Engine DE12TIA.............................................. ............ 104
Tabel 4.10 Data Hasil Penelitian 10 Cause Of Failure Terbesar Pada Analisa
Damage Tear Down Report Engine DE12TIA......................................... ...................105
Tabel 4.11 Data Hasil Pengamatan Bad Lubricating Terhadap Worn ….........……... 108
Tabel 4.12 Data Hasil Pengamatan Fatique Terhadap Worn ………..…….........…... 109
Tabel 4.13 Data Hasil Pengamatan Fatique Terhadap NG Broken … ….........……...110
Tabel 4.14 Data untuk np Chart Seluruh Failure, Ukuran Sampel n = 827 ..... ..........112
Tabel 4.15 Data untuk np Chart Worn (Keausan), Ukuran Sampel n = 827 ... ...........114
Tabel 4.16 Data Untuk np NG Broken Ukuran Sampel n = 827 …………..……….. 116