Perancangan Kebijakan Optimasi Sistem Perawatan Pada Mesin Dibn (double Indian Ballbreaker Net Sorter) Dengan Menggunakan Metode Life Cycle Cost (lcc) Dan Overall Equipment Effectiveness (oee) Di Pt.perkebunan Nusantara Viii Perkebunan Ciater

Abstract

Abstrak PT. Perkebunan Nusantara VIII merupakan perusahaan yang memproduksi teh hitam orthodox di Indonesia. Dikarenakan permintaan akan ekspor teh orthodox yang tinggi, membuat tingginya demand untuk produk teh ini. Dengan tingginya demand akan teh menuntut mesin untuk selalu beroperasi dengan baik. Mesin DIBN (Double Indian Ballbreaker Net Sorter) sering mengalami kerusakan dan memiliki downtime yang tinggi di Departemen Produksi Ruang Layuan & Giling. Hal ini menyebabkan rendahnya tingkat availabilitas mesin pada Departemen Produksi. Diperlukan metode Life Cycle Cost untuk mengetahui jumlah maintenance crew dan retirement age yang optimal dari sebuah mesin. Metode lain yang dapat digunakan adalah Overall Equipment Effectiveness. Overall Equipment Effectiveness digunakan untuk mengukur kinerja dan tingkat efektifitas mesin. Selanjutnya dilakukan analisis terhadap faktor six big losses untuk mengetahui faktor apa yang menyebabkan nilai Overall Equipment Effectiveness rendah. Berdasarkan metode Life Cycle Cost diperoleh nilai Life Cycle Cost terendah sebesar Rp.66,632,538.17 dengan umur optimal mesin 3 tahun dan jumlah maintenance crew sebanyak 3 orang. Berdasarkan metode Overall Equipment Effectiveness, diperoleh nilai Overall Equipment Effectiveness mesin DIBN sebesar 34.49%. Hasil tersebut masih jauh dari standar yang telah ditetapkan oleh Japanese Institute of Plant Maintenance sebesar 85%. Dari six big losses diketahui bahwa faktor yang paling berpengaruh terhadap penurunan efektifitas mesin DIBN adalah faktor idling and minor stoppages (22.87%) dan rework losses (10.52%).

Kata Kunci – Life Cycle Cost, Retirement Age, Maintenance Set Crew, Overall Equipment Effectiveness, Six Big Losses. Abstract PT. Perkebunan Nusantara is a company that produces balck orthodox tea in Indonesia. Because of the high demand for exports, makes the demand of this tea product become high. With the high demand for tea requires the machine to always operate properly. DIBN (Double Indian Ballbreaker Net Sorter) machines are often damaged and have high level of downtime in the Production Department on “Layuan & Giling†workstation. It cause to a low level of machine’s availability in the Production Department. Life Cycle Cost method is needed to know the number of maintenance crew and optimal retirement age of the machine. Another method that can be used is Overall Equipment Effectiveness. Overall Equipment Effectiveness method is used to measure the performance and level of machine effectiveness. Hereafter, the analysis of the six big losses to determine what factors cause the value of Overall Equipment Effectiveness is low. Based on Life Cycle Cost method, the minimum life cycle cost is Rp.66,632,538.17 with the retirement age os DIBN machine is three-year, and consisting of 3 maintenance crew. Based on the Overall Equipment Effectiveness method, the value of Overall Equipment Effectiveness of DIBN machine is 34.49%. The results are still far from the standard set by the Japanese Institute of Plant Maintenance of 85%. From six big losses, it is known that the most influential factor to decrease the effectiveness of DIBN machine is idling and minor stoppages factor (22.87%) and rework losses (10.52%). 

Keywords – Life Cycle Cost, Retirement Age, Maintenance Set Crew, Overall Equipment Effectiveness, Six Big Losses.