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