Analisis risiko kualitas produk pada proses produksi semen di PT Semen Gresik Pabrik Tuban I

Uko, Hendricha Susanty (2011) Analisis risiko kualitas produk pada proses produksi semen di PT Semen Gresik Pabrik Tuban I. Bachelor thesis, Universitas Pelita Harapan.

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Abstract

Dalam upaya menghasilkan produk berkualitas, PT Semen Gresik Pabrik Tuban I seringkali menghadapi berbagai risiko dalam bentuk kerusakan atau gangguan selama proses produksi semen. Oleh karena itu, dibutuhkan adanya pengawasan dan pengendalian secara terus menerus untuk mengurangi kemungkinan terjadinya risiko-risiko kualitas tersebut. Pada penelitian ini, digunakan metode FMEA untuk mengidentifikasi risiko-risiko kualitas dalam proses produksi semen dan melakukan penilaian terhadap tingkat kemungkinan terjadinya risiko serta tingkat keseriusan dampak yang dapat ditimbulkan. Hasil FMEA menunjukkan bahwa terdapat 19 risiko kualitas dalam proses produksi semen. Dari 19 risiko kualitas yang teridentifikasi, melalui probability-impact matrix, dapat diketahui risiko-risiko yang tergolong kritis dan harus segera dimitigasi. Risiko-risiko kritis tersebut antara lain, risiko material basah, flushing, kebuntuan transportasi dan material berukuran besar. Simulasi Monte Carlo digunakan dalam mengevaluasi risiko kritis yang dipengaruhi oleh faktor internal dan dapat dikontrol. Risiko tersebut yakni kebuntuan transportasi material yang disebabkan karena kerusakan peralatan transportasi akibat kurangnya pemeliharaan. Dalam hal ini, simulasi dilakukan untuk mengetahui rata-rata waktu kerusakan dan rata-rata waktu perbaikan sehingga dapat ditentukan kapan waktu pemeliharaan yang optimal dapat dilakukan. Hasil simulasi menunjukkan bahwa rata-rata waktu kerusakan adalah setelah peralatan beroperasi selama 115.1636 jam dengan rata-rata waktu perbaikan selama 1.1624 jam. Dengan demikian upaya mitigasi yang dapat dilakukan adalah dengan melakukan pemeliharaan pencegahan sebelum rata-rata waktu kerusakan tersebut. Mitigasi lainnya terhadap risiko-risiko kritis antara lain meliputi pemeliharaan kebersihan mesin, inspeksi rutin selama proses produksi berlangsung, penambahan jumlah operator, dokumentasi FMEA serta peningkatan koordinasi dan komunikasi. / In an effort to produce quality products, PT Semen Gresik Pabrik Tuban I often face various risks in the form of damage or disruption during production process. Therefore, needed the supervision and controlling during production process to minimize probability of quality risk occurrence. In this research, FMEA is used to identify quality risks in cement production process and to assess the level of risk probability (occurrence) and risk impact (severity). FMEA results indicate that there are 19 quality risks in cement production process. Through probability-impact matrix, can be seen that there are some critical quality risks and must be mitigated. Critical risks include, the risk of wet material, flushing, disruption of material transportation and size of material that too big (out of material specification). Monte Carlo simulation are used to evaluate critical risks that influenced by internal factors and controllable factors. The risk is disruption of material transportation that caused by machine failure due to lack of machine maintenance. In this case, the simulations are performed to determine mean time between failure and mean time to repair, so can be decided when the optimal preventive maintenance can be performed. The simulation results show that the mean time between failure is 115.1636 hours and mean time to repair is 1.1624 hours. Thus, mitigation effort that can be done is through preventive maintenance before that mean time between failure. Other mitigations of critical risks include maintenance of machine cleanliness, routine inspection during production process, increasing the number of operators, FMEA documentation, and communication and coordination improvement.

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