viii
DAFTAR ISI
LEMBAR PENGESAHAN PEMBIMBING .................................................... iii
HALAMAN PENGESAHAN PENGUJI .......................................................... iv
HALAMAN PERNYATAAN KEASLIAN JUDUL TUGAS AKHIR............ v
KATA PENGANTAR......................................................................................... vi
DAFTAR ISI .....................................................................................................viii
DAFTAR TABEL .............................................................................................. xii
DAFTAR GAMBAR.......................................................................................... xv
ABSTRAK ......................................................................................................... xvi
BAB I..................................................................................................................... 1
1.1 LATAR BELAKANG................................................................... 1
1.2 PERUMUSAN MASALAH.......................................................... 4
1.3 PEMBATASAN MASALAH ....................................................... 4
1.4 TUJUAN PENELITIAN ............................................................... 5
1.5 MANFAAT ................................................................................... 5
1.6 SISTEMATIKA PENULISAN LAPORAN ................................. 5
BAB II ................................................................................................................... 7
2.1 MAINTENANCE............................................................................ 7
2.2 TUJUAN MAINTENANCE ........................................................... 7
2.3 KLASIFIKASI MAINTENANCE .................................................. 9
2.3.1 Planned Maintenance .............................................................. 9
2.3.2 Unplanned Maintenance ....................................................... 12
ix
2.4 RELIABILITY .............................................................................. 13
2.4.1 Definisi Keandalan ................................................................ 13
2.4.2 Manfaat Keandalan................................................................ 15
2.5 IDENTIFIKASI SPAREPART MENGGUNAKAN METODE
ABC ANALYSIS ............................................................................ 15
2.6 MODEL DISTRIBUSI DATA DALAM KEANDALAN.......... 16
2.6.1 Model Distribusi Gausian ..................................................... 17
2.6.2 Model Distribusi Logormal ................................................... 19
2.6.3 Model Distribusi Eksponensial ............................................. 20
2.6.4 Model Distribusi Weibull ...................................................... 21
2.7 IDENTIFIKASI DAN PARAMETER DISTRIBUSI................. 23
2.7.1 Identifikasi Distribusi Awal .................................................. 23
2.7.2 Estimasi Parameter ................................................................ 24
2.8 MODEL PERAWATAN............................................................. 26
2.8.1 Model Perawatan Pencegahan Probabilitas........................... 26
2.8.2 Model Age Replacement........................................................ 27
BAB III................................................................................................................ 30
3.1 METODOLOGI PENELITIAN .................................................. 30
3.2 SUMBER DATA PENELITIAN ................................................ 30
3.2.1 Studi Lapangan...................................................................... 30
3.2.2 Studi Literatur........................................................................ 30
x
3.3 PERUMUSAN MASALAH........................................................ 31
3.4 TUJUAN PENELITIAN ............................................................. 31
3.5 PENGUMPULAN DATA........................................................... 31
3.5.1 Pemilihan Sparepart Kritis Dengan Menggunakan ABC
Analysis ................................................................................. 31
3.5.2 Pengujian Model Distribusi Waktu Kerusakan ..................... 32
3.5.3 Menentukan Nilai MTTF (Mean Time To Failure) .............. 32
3.5.4 Menentukan Nilai Cost of Failure dan Cost of Preventive ... 32
3.5.5 Penentuan Periode Optimum Penggantian Sparepart ........... 33
3.5.6 Menentukan Biaya Kondisi Sekarang dan Usulan ................ 34
3.5.7 Pembahasan ........................................................................... 34
3.5.8 Kesimpulan dan Saran........................................................... 34
BAB IV................................................................................................................ 36
4.1 HASIL PENELITIAN................................................................. 36
4.1.1 Pengumpulan Data ................................................................ 36
4.1.2 Data Sparepart Rubber Tyred Gantry ................................... 36
4.2 PENGOLAHAN DATA.............................................................. 38
4.2.1 Klasifikasi Sparepart Berdasarkan ABC Analisys ................ 38
4.2.2 Pemilihan Model Distribusi Kerusakan................................. 42
4.2.3 Menentukan Nilai Parameter Distribusi ................................ 68
4.2.4 Menetukan Nilai MTTF (Mean Time To Failure) ................ 71
xi
4.2.5 Menentukan Nilai Cost of Failure dan Cost of Preventive ... 72
4.2.6 Menentukan Interval Waktu Penggantian Pencegahan ......... 78
4.2.7 Menentukan Nilai Biaya Perawatan Sekarang dan Usulan ... 89
4.3 PEMBAHASAN ......................................................................... 93
4.3.1 Pemilihan Sparepart Kritis.................................................... 93
4.3.2 Pemilihan Model Distribusi................................................... 94
4.3.3 Menentukan nilai Mean Time To Failure dan Parameter...... 94
4.3.4 Menentukan Selang Waktu Penggatian................................. 95
4.3.5 Biaya Perawatan Sekarang dan Usulan ................................. 96
BAB V ................................................................................................................. 99
5.1 KESIMPULAN ........................................................................... 99
5.2 SARAN ..................................................................................... 100
DAFTAR PUSTAKA....................................................................................... 101
LAMPIRAN ..................................................................................................... 102
xii
DAFTAR TABEL
Tabel 4.1 Daftar Frekuensi Kerusakan Sparepart Rubber Tyred Gantry Periode
Januari 2013 – Juli 2017 ....................................................................................... 37
Tabel 4.2 Daftar Jenis, Jumlah, Frekuensi dan Harga Sparepart Rubber Tyred
Gantry Crane Periode Januari 2013 – Juli 2017................................................... 38
Tabel 4.3 Analisa Harga Total Sparepart Rubber Tyred Gantry Cranes............. 39
Tabel 4.4 Analisa Persentase Nilai Sparepart Rubber Tyred Gantry .................. 40
Tabel 4.5 Hasil Rekapitulasi Klasifikasi Sparepart Menurut Teori ABC ........... 41
Tabel 4.6 Data Interval Waktu Kerusakan Sparepart Wirerope Periode 2013 -
2017....................................................................................................................... 42
Tabel 4.7 Perhitungan Index of Fit dengan Distribusi Normal Sparepart
Wirerope................................................................................................................ 44
Tabel 4.8 Perhitungan Index of Fit dengan Distribusi Lognormal pada Sparepart
Wirerope................................................................................................................ 45
Tabel 4.9 Perhitungan Index of Fit dengan Distribusi Eksponensial pada
Sparepart Wirerope............................................................................................... 46
Tabel 4.10 Perhitungan Index of Fit dengan Distribusi Weibull pada Sparepart
Wirerope................................................................................................................ 47
Tabel 4.11 Rekapitulasi Perhitungan Index of Fit Sparepart Wirerope ............... 48
Tabel 4.12 Data Interval Waktu Kerusakan Sparepart Solid-State Rev Contactor
Periode 2013 - 2017 .............................................................................................. 49
Tabel 4.13 Perhitungan Index of Fit dengan Distribusi Normal Sparepart Solid-
State Rev Contactor............................................................................................... 50
Tabel 4.14 Perhitungan Index of Fit dengan Distribusi Lognormal Sparepart
Solid-State Rev Contactor ..................................................................................... 52
xiii
Tabel 4.15 Perhitungan Index of Fit dengan Distribusi Eksponensial Sparepart
Solid-State Rev Contactor ..................................................................................... 53
Tabel 4.16 Perhitungan Index of Fit dengan Distribusi Weibull Sparepart Solid-
State Rev Contactor............................................................................................... 54
Tabel 4.17 Rekapitulasi Perhitungan Index of Fit Sparepart Solid-State Rev
Contactor .............................................................................................................. 55
Tabel 4.18 Data Interval Waktu Kerusakan Sparepart Limit Switch Trolley
Periode 2013 - 2017 .............................................................................................. 55
Tabel 4.19 Perhitungan Index of Fit dengan Distribusi Normal Sparepart Limit
Swith Trolley ......................................................................................................... 57
Tabel 4.20 Perhitungan Index of Fit dengan Distribusi Lognormal Sparepart
Limit Swith Trolley ................................................................................................ 58
Tabel 4.21 Perhitungan Index of Fit dengan Distribusi Eksponensial Sparepart
Limit Swith Trolley ................................................................................................ 59
Tabel 4.22 Perhitungan Index of Fit dengan Distribusi Weibull Sparepart Limit
Swith Trolley ......................................................................................................... 61
Tabel 4.23 Rekapitulasi Perhitungan Index of Fit Sparepart Limit Swith Trolley 61
Tabel 4.24 Data Interval Waktu Kerusakan Sparepart Brake Pad Set Gantry
Periode 2013 - 2017 .............................................................................................. 62
Tabel 4.25 Perhitungan Index of Fit dengan Distribusi Normal Sparepart Brake
Pad Set Gantry ...................................................................................................... 63
Tabel 4.26 Perhitungan Index of Fit dengan Distribusi Lognormal Sparepart
Brake Pad Set Gantry............................................................................................ 65
Tabel 4.27 Perhitungan Index of Fit dengan Distribusi Eksponensial Sparepart
Brake Pad Set Gantry............................................................................................ 66
Tabel 4.28 Perhitungan Index of Fit dengan Distribusi Weibull Sparepart Brake
Pad Set Gantry ...................................................................................................... 67
Tabel 4.29 Rekapitulasi Perhitungan Index of Fit Brake Pad Set Gantry............ 68
xiv
Tabel 4.30 Model Distribusi Terpilih Data Interval Waktu Kerusakan Tiap
Sparepart............................................................................................................... 68
Tabel 4.31 Perhitungan Parameter Sparepart Wirerope ...................................... 69
Tabel 4.32 Perhitungan Parameter Sparepart Solid-State Rev Contactor............ 69
Tabel 4.33 Perhitungan Parameter Sparepart Limit Swith Trolley ...................... 70
Tabel 4.34 Perhitungan Parameter Sparepart Brake Pad Set Gantry .................. 70
Tabel 4.35 Parameter Distribusi Kerusakan Sparepart Rubber Tyred Gantry .... 71
Tabel 4.36 Perhitungan Interval Waktu Penggantian Optimum Sparepart
Wirerope................................................................................................................ 80
Tabel 4.37 Perhitungan Interval Waktu Penggantian Optimum Sparepart Solid-
State Rev Contactor............................................................................................... 83
Tabel 4.38 Perhitungan Interval Waktu Penggantian Optimum Sparepart Limit
Switch Trolley ....................................................................................................... 85
Tabel 4.39 Perhitungan Interval Waktu Penggantian Optimum Sparepart Brake
Pad Set Gantry ...................................................................................................... 88
Tabel 4.40 Interval Waktu Penggantian Optimum dan Ekspetasi Biaya
Penggantian Sparepart Kritis Rubber Tyred Gantry Cranes................................. 91
Tabel 4.41 Rekapitulasi Interval Waktu Penggantian Sparepart Rubber Tyred
Gantry Cranes Sekarang dan Usulan.................................................................... 93
Tabel 4.42 Nilai Parameter Distribusi dan Nilai MTTF Tiap Sparepart ............. 95
Tabel 4.43 Total Perbandingan Nilai Biaya Sparepart Rubber Tyred Gantry..... 97
xv
DAFTAR GAMBAR
Gambar 1.1 Rubber Tyred Gantry Serie E-One2 .................................................. 2
Gambar 2.1 Klasifikasi Maintenance .................................................................... 9
Gambar 2.2 Klasifikasi ABC Analysis ............................................................... 16
Gambar 2.3 Kurva Distribusi Normal ................................................................ 19
Gambar 2.4 Kurva Distribusi Lognormal............................................................ 20
Gambar 2.5 Kurva Distribusi Eksponensial ........................................................ 21
Gambar 2.6 Kurva Distribusi Weibull................................................................. 23
Gambar 2.7 Model Perawatan Perencanaan dan Perbaikan Kerusakan .............. 26
Gambar 2.8 Model Age Replacement .................................................................. 28
Gambar 2.9 Kebijakan Perawatan Penggantian Pencegahan .............................. 28
Gambar 3.1 Flowchart Metodologi Penelitian .................................................... 35
Gambar 4.1 Main Components Rubber Tyred Gantry ........................................ 36
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