FINAL PROJECT – RM 1522

STUDY OF FMEA AND RELIABILITY

AT 3rd PLANT COAL MILL UNITS
PT. SEMEN GRESIK, Tbk

HENRY YAF
NRP 2102 100 025

Academic Supervisor
Dr. Ir. Agus Sigit Pramono, DEA

MECHANICAL ENGINEERING DEPARTMENT

Faculty of Industrial Technology
Sepuluh Nopember Institute of Technology
Surabaya 2007
TUGAS AKHIR – RM 1522

STUDI RELIABILITY DAN FMEA

PADA UNIT COAL MILL PROYEK TUBAN III
PT. SEMEN GRESIK, Tbk

HENRY YAF
NRP 2102 100 025

Dosen Pembimbing
Dr. Ir. Agus Sigit Pramono, DEA

JURUSAN TEKNIK MESIN

Fakultas Teknologi Industri
Institut Teknologi Sepuluh Nopember
Surabaya 2007
 STUDI RELIABILITY DAN FMEA PADA UNIT
COAL MILL PROYEK TUBAN III
PT. SEMEN GRESIK, Tbk

TUGAS AKHIR
Diajukan untuk memenuhi salah satu syarat
Memperoleh gelar Sarjana Teknik
pada
Bidang studi Desain
Program studi S-1 Jurusan Teknik Mesin
Fakultas Teknologi Industri
Institut Teknologi Sepuluh Nopember

Oleh :
HENRY YAF
NRP. 2102.100.025

Disetujui oleh tim penguji Tugas Akhir :

1. Dr. Ir. Agus Sigit Pramono, DEA ................ (Pembimbing)

2. Ir. Yusuf Kaelani, M.Eng ...................... (Penguji I)

3. Ir. Julendra B. Ariatedja ..................... (Penguji II)

4. Ir. Arie Juwono ................... (Penguji III)

SURABAYA
JULI, 2007
 STUDI RELIABILITY DAN FMEA PADA UNIT
COAL MILL PROYEK TUBAN III
PT. SEMEN GRESIK, Tbk

Nama mahasiswa : Henry Yaf

NRP : 2102.100.025
Jurusan : Teknik Mesin FTI-ITS
Dosen Pembimbing : Dr. Ir. Agus Sigit Pramono, DEA

Abstrak
Penerapan konsep Reliability dan Failure Mode and Effect
Analysis (FMEA) dalam proses maintenance suatu alat
membutuhkan analisa tersendiri berdasarkan data histori
kerusakan mesin.
Analisa Realibility digunakan untuk menentukan nilai
failure rate, MTBF, MTTR, Reliability, dan Availability.
Sedangkan analisa FMEA digunakan untuk menentukan strategi
perawatan yang optimum berdasarkan tiap failure mode
kerusakan mesin dari hasil analisa diagram pareto serta untuk
menentukan Fault Tree Analysis (FTA) sehingga dapat ditentukan
jenis perawatan yang optimum.
Kesimpulan yang didapat dari hasil analisa kuantitatif
adalah waktu MTBF 5 mesin kritis 463.BC5 = 3373,47 jam,
473.WF1 = 2060,16 jam 473.RM1 = 862,65 jam, 483.CP1 =
1777,24 jam, 483.CP2 = 3950,64 jam. Sedang untuk kebijakan
strategi perawatan dari analisa kualitatif di dapat On-condition
task = 0 item, Schedule restoration task = 3 item, Schedule
discard task = 5 item, Failure finding task = 4 item, re-design
task = 2 item.

Kata kunci : Downtime, Bottleneck, MTBF, MTTR,

Reliability, Availability, Failure mode,
FMEA, FTA
STUDY OF FMEA AND RELIABILITY AT 3rd PLANT
COAL MILL UNITS, PT. SEMEN GRESIK,Tbk

Student : Henry Yaf

NRP : 2102.100.025
Department : Mechanical Engineering FTI-ITS
Supervisor : Dr. Ir. Agus Sigit Pramono, DEA

Abstract,
Reliability and Failure Mode and Effect Analysis (FMEA)
consept aplication in maintenance process of a machine is
require specific analysis based on machine historical data.
Reliability analysis is used to determine the value of
failure rate, MTBF, MTTR, Reliability and Availbility. Whereas,
FMEA analysis is used to determine the optimum maintenance
strategy based on each of failure mode of failure machine from
the result of pareto diagram. And it also used to determine the
Fautl Tree Analysis (FTA) so that maintenance method would be
assigmed.
The end of study from Quantitative analysis were value of
five critical machine at line, 463.BC5 = 3373,74 hours, 473.WF1
= 2060,16 hours, 473.RM1 = 862,65 hours, 483.CP1 = 1777,24
hours and 483.CP2 = 3950,64 hours. Meanwhile from Qualitatif
analysis were On-condition task = 0 item, Schedule restorion = 3
item, Schedule discard task = 5 item, Failure finding task = 4
item, re-design = 2 item. So that maintenance strategy could be
assigned.

Word Key : Downtime, Bottleneck, MTBF, MTTR, Reliability,

Availability, Failure mode, FMEA, FTA
 KATA PENGANTAR

Segala puji hanya bagi Alloh ‘azza wa jalla yang telah

memberikan rahmat dan hidayah-Nya kepada kita sehingga kita
masih diberikan kesempatan untuk terus meningkatkan iman dan
ketakwaan kita kepada-Nya. Sholawat serta salam semoga
tercurah kepada Rosululloh Muhammad Sholollohu’alaihi
wasallam juga para keluarga beserta sahabat dan pengikutnya
hingga akhir zaman nanti.
Alhamdulillah kami panjatkan kepada Alloh Subhanahu
wa Ta’ala atas ijin dan rahmat-Nya kami dapat menyempurnakan
penyusunan Tugas Akhir ini. Tugas ini kami disusun guna
memenuhi persyaratan akademis menyelesaikan program strata-1
Jurusan Teknik Mesin, FTI-ITS.
Penulis menyadari bahwa tidak mungkin bisa Tugas
Akhir ini selesai tanpa bantuan dari berbagai pihak terkait. Tak
lupa penulis juga menyampaikan rasa terima kasih yang dalam
kepada :
1. Bapak Dr. Ir. Agus Sigit Pramono, DEA selaku dosen
pembimbing yang telah meluangkan banyak waktunya
untuk memberi bimbingan dalam penulisan Tugas Akhir
ini hingga selesai.
2. Bapak Ir. Yusuf Kaelani, MSc.E, Julendra B Ariatedja,
ST, MT dan Ir. Arie Juwono yang telah memberikan
kasukan demi kesempurnaan Tugas Akhir ini.
3. Bapak dan Ibu di rumah yang selalu mendoakan dan
memberikan semangat untuk segera menyelesaikan
Tugas Akhir ini.
4. Seluruh dosen dan karyawan Jurusan Teknik Mesin ITS
yang telah memberikan ilmu pengetahuan dan atas
kerjasamanya selama ini.
5. Rekan-rekan seperjuangan M-45 dan Study Club Desain :
Roghib, Farid, Oki Sum, Agus-Kemat-, Anang WR
(Teman KP-1), Dono (Teman KP-2), Reno, dll terima
kasih atas dukungan dan kerjasamanya selama kuliah
 6. Mas Rohman, yang sabar dalam membimbing baik di
lapangan atau menjawab pertanyaan penyusun, Pak Didit
DW dan semua karyawan atas ijin dan kesempatan yang
telah diberikan sehingga penyusun dapat melakukan
penelitian di PT. Semen Gresik, Tbk
7. Rekan-rekan Ustadz dan Ustadzah TPA Baitul Muttaqin
Keputih-Sukolilo yang selalu memberikan semangat
untuk selalu sabar dan istiqomah di Jalan-Nya serta
mengikuti Sunnah Rasul-Nya: Rikhal, Maramis, Adhy,
Iwan, Rosyied, Anton, Dendy. Semoga Alloh tetap
menjaga Ukhuwah yang telah kita bina selama ini..
8. Imam IM, Terima kasih atas peminjaman printernya,
semoga Alloh membalas kebaikanmu Imam.
9. Rekan-rekan kos-kosan Keputih ID/48, Terima kasih atas
kerjasamanya selama ini.

Penulis menyadari bahwa Tugas Akhir ini masih banyak

kekurangannya sehingga saran dan kritik sangat diperlukan guna
kesempurnaan Tugas Akhir ini. Semoga Tugas Akhir ini
bermanfaat bagi semua pihak yang membutuhkan. Amin.

Surabaya, 19 Juli 2007

Penulis
 DAFTAR ISI

JUDUL .................................................................................... i
LEMBAR PENGESAHAN ................................................... iii
ABSTRAK .............................................................................. iv
KATA PENGANTAR .............................................................vi
DAFTAR ISI ........................................................................... viii
DAFTAR GAMBAR .............................................................. xiv
DAFTAR TABEL ................................................................... xvi
DAFTAR EQUIPMENT NUMBER ...................................... xx
DAFTAR LAMPIRAN ........................................................... xxii

BAB I PENDAHULUAN
1.1 Latar Belakang Permasalahan .......................... 1
1.2 Perumusan Masalah ......................................... 3
1.3 Batasan Masalah .............................................. 3
1.4 Tujuan Penelitian ............................................. 4
1.5 Manfaat Penelitian ........................................... 5

BAB II DASAR TEORI

2.1 Reliability ......................................................... 7
2.1.1 Penilaian Keandalan .......................... 10
2.1.2 Laju Kegagalan .................................. 11
2.1.3 Mean Time Between Failure (MTBF) 11
2.1.4 Mean Time To Repair MTTR) ...........12
2.2 Karakteristik Kegagalan ................................... 12
2.3 Availability ....................................................... 14
2.4 Analisa Sistem atau Peralatan Kritis
(Integrasi MCDM) ............................................15
2.4.1 Teori Analytical Hierarchy Process
Under Certainity .................................16
2.4.2 Penentuan Beban Relatif ....................16
2.4.3 Multiple Criteria Decision
Making (MCDM) ...............................17
2.4.4 Konsistensi dari Comparison Matrik . 19
 2.5 Distribusi data Waktu Antar Kegagalan ...........20
2.5.1 Distribusi Eksponensial ......................20
2.5.2 Distribusi Weibull .............................. 21
2.5.3 Distribusi Normal ...............................22
2.5.4 Distribusi Lognormal ......................... 23
2.6 Pengujian Distribusi ......................................... 23
2.7 Functional Block Diagram ................................24
2.8 Failure Mode and Effect Analysis (FMEA) ..... 25
2.8.1 Deskripsi dan fungsi FMEA .............. 25
2.8.2 Langkah-langkah menyusun FMEA .. 25
2.8.3 FMEA Worksheet .............................. 26
2.9 Diagram Pareto ................................................. 27
2.10 Fault Tree Analysis .......................................... 27
2.10.1 Deskripsi dan Fungsi FTA ................. 27
2.10.2 Langkah-langkah menyusun FTA ..... 28
2.10.3 Simbol-simbol FTA ........................... 28
2.11 Perawatan ..........................................................29
2.11 1 Strategi Perawatan ..............................30
2.11.2 Tindakan Perawatan ...........................32
2.11.2.1 Failure Consequences .............. 32
2.11.2.2 Proactive Task ......................... 33
2.11.2.3 Default Action ......................... 34
2.11.2.4 Kebijakan Perawatan ............... 34

BAB III METODOLOGI PENELITIAN

3.1 Studi Lapangan ................................................. 39
3.2 Studi Kepustakaan ............................................ 43
3.3 Identifikasi dan Perumusan Masalah ................44
3.4 Identifikasi Variabel dan Pengumpulan Data ...44
3.5 Pengolahan dan Analisa Data ........................... 44
3.6 Kesimpulan dan Saran ...................................... 46
3.7 Diagram Alir Penelitian ....................................46

BAB IV PENENTUAN PERALATAN KRITIS

4.1 Kriteria Kritis ....................................................49
 4.2 Penentuan Peralatan Kritis ................................49
4.2.1 Data Historical Mesin ........................ 49
4.2.2 Multiple Criteria Decisio
Making (MCDM) ...............................51
4.2.2.1 MCDM dari Bottleneck Mesin 52
4.2.2.2 MCDM dari Frekuensi Keru-
sakan Mesin ............................. 60
4.2.2.3 MCDM dari Downtime Mesin . 68
4.2.3 Composite Respective Weight ........... 76

BAB V ANALISA KEANDALAN SECARA KUANTITATIF

5.1 Penilaian Keandalan Mesin-mesin Unit
Coal Mill ...........................................................81
5.1.1 Analisa Keandalan Roller
Mill (473.RM1) ..................................81
5.1.1.1 TBF Roller Mill ...........................81
5.1.1.2 Uji Distribusi Data TBF
Roller Mill ................................... 82
5.1.1.3 Pdf Roller Mill ............................ 83
5.1.1.4 Reliability Roller Mill ................. 85
5.1.1.5 Failure Rate Roller Mill .............. 87
5.1.1.6 MTBF Roller Mill ....................... 88
5.1.2 Analisa Keandalan
Compressor (483.CP1) .......................89
5.1.2.1 TBF Compressor ......................... 89
5.1.2.2 Uji Distribusi Data
TBF Compressor ......................... 90
5.1.2.3 Pdf Compressor ........................... 90
5.1.2.4 Reliability Compressor ............... 92
5.1.2.5 Failure Rate Compressor .............94
5.1.2.6 MTBF Compressor ......................95
5.1.3 Analisa Keandalan Weigh
Feeder (473.WF1) .............................. 96
5.1.3.1 TBF Weigh Feeder ...................... 96
5.1.3.2 Uji Distribusi Data TBF
 Weight Feeder ............................ 96
5.1.3.3 Pdf Weigh Feeder ........................97
5.1.3.4 Reliability Weigh Feeder ............ 99
5.1.3.5 Failure Rate Weigh Feeder ..........100
5.1.3.6 MTBF Weigh Feeder ...................102
5.1.4 Analisa Keandalan Belt
Conveyor (463.BC5) ..........................102
5.1.4.1 TBF Belt Conveyor ..................... 102
5.14.2 Uji Distribusi Data TBF
Belt Conveyor ............................. 103
5.1.4.3 Pdf Belt Conveyor ......................103
5.1.4.4 Reliability Belt Conveyor ............105
5.1.4.5 Failure Rate Belt Conveyor .........107
5.1.4.6 MTBF Belt Conveyor ..................108
5.1.5 Analisa Keandalan
Compressor (483.CP2) ......................109
5.1.5.1 TBF Compressor ......................... 109
5.1.5.2 Uji Distribusi Data TBF
Compressor ..................................109
5.1.5.3 Pdf Compressor ........................... 110
5.1.5.4 Reliability Compressor ............... 111
5.1.5.5 Failure Rate Compressor .............113
5.1.5.6 MTBF Compressor ......................115
5.2 Perhitungan Availability Mesin-mesin
Unit Coal Mill ...................................................115
5.2.1 Availability Mesin Roller
Mill (473.RM1) ..................................116
5.2.1.1 Waktu Repair Roller Mill ............116
5.2.1.2 Uji Distribusi Data Waktu
Repair Roller Mill ....................... 118
5.2.1.3 MTTR Rollr Mill ........................ 119
5.2.1.4 Availability Roller Mill ...............119
5.2.2 Availability Mesin
Compressor (483.CP1) .......................120
5.2.2.1 Waktu Repair Compressor .......... 120
 5.2.2.2 Uji Distribusi Data Waktu
Repair Compressor ......................121
5.2.2.3 MTTR Compressor .................... 122
5.2.2.4 Availability Compressor ............. 122
5.2.3 Availability Mesin Weight
Feeder (473.WF1) ............................ 123
5.2.3.1 Waktu Repair Weight
Feeder (473.WF1) ....................... 123
5.2.3.2 Uji Distribusi Data Waktu Repair
We-Feeder .................................. 124
5.2.3.3 MTTR Weight Feeder ..................124
5.2.3.4 Availability Weight Feeder ......... 125
5.2.4 Availability Mesin Belt
Conveyor (463.BC5) ........................ 126
5.2.4.1 Waktu Repair Belt Conveyor ...... 126
5.2.4.2 Uji Distribusi Data Waktu
Repair Belt Conveyor ..................126
5.2.4.3 MTTR Belt Conveyor ................. 127
5.2.4.4 Availability Belt Conveyor ..........128
5.2.5 Availability Mesin Compresor
(483.CP2) ......................................... 128
5.2.4.1 Waktu Repair Compresor ............128
5.2.4.2 Uji Distribusi Data Waktu
Repair Compresor ....................... 129
5.2.4.3 MTTR Compresor ....................... 133
5.2.4.4 Availability Compresor ............... 137

BAB VI ANALISA KEANDALAN SECARA KUALITATIF

6.1 Pemilihan Sistem dan Pengumpulan Informasi 133
6.2 Pendefinisian Boundary System .......................134
6.3 Functional Block Diagram (FBD) .................... 139
6.3.1 FBD Belt Conveyor (463.BC5) ........139
6.3.2 FBD Weight Feeder (473.WF1) .......142
6.3.3 FBD Roller Mill (473.RM1) .............144
6.3.4 FBD Compressor (473.CP1&CP2) .. .147
 6.3.5 System Function dan System failure .150
6.4 Failure Mode And Effect Analysis (FMEA) .... .152
6.5 Diagram Pareto ................................................. .158
6.5.1 Diagram Pareto (463.BC5) ................159
6.5.2 Diagram Pareto (473.WF1) ...............160
6.5.3 Diagram Pareto (473.RM1) ...............161
6.5.4 Diagram Pareto (483.CP1&CP2) ..... .163
6.6 Fault Tree Analysis (FTA) .................................164
6.7 Management Maintenance .................................165
6.7.1 Failure Consequence ........................ .166
6.7.2 Proactive Task ...................................168
6.7.3 Default Question ................................169
6.7.4 Proposed Task .................................. .170
6.7.5 Pelaku Proposed Task (Execute) .......171
6.7.6 Perencanaan Kebijakan Perawatan ....171

BAB VII KESIMPULAN

7.1 Kesimpulan ........................................................177
7.2 Saran ................................................................. .178

DAFTAR PUSTAKA ............................................................ .179

 DAFTAR GAMBAR

Gambar 2.1 Grafik Reliability fungsi waktu .....................9

Gambar 2.2 Grafik Cumulatif Distribution Function ........9
Gambar 2.3 Grafik Probability Density Function ............. 10
Gambar 2.4 Baththub Curve ..............................................13
Gambar 2.5 Maintenance Delay ........................................14
Gambar 2.6 Functional Block Diagram System ................25
Gambar 2.7 FMEA Worksheet ......................................... 26
Gambar 2.8 Pareto Diagram ..............................................27
Gambar 2.9 Bagan Sistem Perawatan ............................... 32
Gambar 2.10 Decision Worksheet .......................................35
Gambar 2.11 Decision Diagram ..........................................38
Gambar 3.1 Proses Coal Mill ............................................43
Gambar 3.2 Diagram Alir Penelitian ................................ 47
Gambar 5.1 Grafik Pdf Roller Mill (473.RM1) ................ 85
Gambar 5.2 Grafik Keandalan Roller Mill (473.RM1) .....86
Gambar 5.3 Nilai failure rate (473.RM1) ......................... 88
Gambar 5.4 Grafik Pdf Roller Mill (473.RM1) ................ 92
Gambar 5.5 Grafik Keandalan Compressor (483.CP1) .... 93
Gambar 5.6 Laju Kerusakan Compressor (483.CP1) ....... 95
Gambar 5.7 Grafik Pdf Weight Feeder (483.WF1) ...........98
Gambar 5.8 Grafik Keandalan Weight Feeder (48.WF1) . 100
Gambar 5.9 Laju Kerusakan Weight Feeder (483.WF1) .. 101
Gambar 5.10 Grafik Pdf Belt Conveyor (463.BC5) ...........105
Gambar 5.11 Grafik Keandalan Belt Conveyor (463.BC5) .106
Gambar 5.12 Grafik Laju Krusakan B-Conveyor (463.BC5)108
Gambar 5.13 Grafik Pdf Compressor (483.CP2) ...............111
Gambar 5.14 Grafik Keandalan Compressor (483.CP2) .... 113
Gambar 5.15 Grafik Laju Kerusakan Compresor (483.CP2)114
Gambar 5.16 Maintenance Downtime .................................116
Gambar 6.1 Pemodelan Sistem PT Semen Gresik
Pabrik Tuban ................................................. 135
Gambar 6.2 Pemodelan Sistem Produksi Pabrik Tuban III135
Gambar 6.3 Pemodelan Sistem Produksi Clinker ............. 137
Gambar 6.4 Physical Boundary Coal Mill Tuban III ........138
Gambar 6.5 Functional Block Diagram 463.BC5 ……… 141
Gambar 6.6 Functional Block Diagram 473.WF1 ………143
Gambar 6.7 Functional Block Diagram 473.RM1 ………146
Gambar 6.8 Functional Block Diagram 483.CP1 ……….149
Gambar 6.9 Flowchart Penentuan nilai RPN .................... 158
Gambar 6.10 Diagram Pareto Kerusakan 463.BC5 ............ 159
Gambar 6.11 Diagram Pareto Kerusakan 473.WF1 ............160
Gambar 6.12 Diagram Pareto Kerusakan 473.RM1 ........... 162
Gambar 6.13 Diagram Pareto Kerusakan 483.CP1 .............163
Gambar 6.14 Decision Worksheet ...................................... 165
Gambar 6.15 Penggisian decision worksheet untuk
mencatat failure consequences ...................... 167
 DAFTAR TABEL

Tabel 2.1 Simbol-Simbol dalam penyusunan FTA ..........28

Tabel 3.1 Downtime mechanical maintenance
periode Januari – Maret 2006 .......................... 40
Tabel 3.2 Historical penggantian pemumas reducer ........41
Tabel 3.3 Tabel penyebab kerusakan Raw Mill ...............42
Tabel 3.4 Struktur Hirarki proses unit Coal Mill .............42
Tabel 4.1 Frekuensi Kerusakan dan rata-rata
Downtime Mesin ..............................................50
Tabel 4.2 Prioritas Bottleneck dari mesin-mesin
Coal Mill ..........................................................51
Tabel 4.3 Tabel Perbandingan Nilai Bottleneck
antar Mesin ......................................................52
Tabel 4.4 Matrik Prioritas Bottlenneck (22 x 22) ............54
Tabel 4.5 Normalized Matriks Prioritas
Bottlenneck (22 x 22) ...................................... 56
Tabel 4.6 Matrik Row Average Prioritas Bottleneck .......58
Tabel 4.7 Nilai n max Row Average ............................... 59
Tabel 4.8 Tabel Perbandingan Frekuensi Kerusakan
antar Mesin ...................................................... 61
Tabel 4.9 Matrik Frekuensi Kerusakan Mesin (22 x 22) .64
Tabel 4.10 Normalized Matriks Frekuensi
Kerusakan (22 x 22) ........................................ 66
Tabel 4.11 Tabel Matrik Row Average Frekuensi
Kerusakan ........................................................ 67
Tabel 4.12 Tabel Perbandingan Downtime antar Mesin ... 69
Tabel 4.13 Matrik Downtime Mesin (22 x 22) ..................72
Tabel 4.14 Normalized Matriks Downtime
Mesin (22 x 22) ................................................74
Tabel 4.15 Tabel Matrik Row Average Downtime Mesin .75
Tabel 4.16 Row Average masing-masing Kriteria .............77
Tabel 4.17 Composite Respective Weight .........................78
Tabel 4.18 Top Ten The Worst Machine ...........................79
Tabel 5.1 Waktu antar Kegagalan (TBF)
 Roller Mill (473.RM1) ................................... 81
Tabel 5.2 Hasil Pengujian TBF Roller Mill (473.RM1) ...83
Tabel 5.3 Nilai Pdf dari Roller Mill (473.RM1) ............. 84
Tabel 5.4 Nilai Keandalan Roller Mill (473.RM1) ..........86
Tabel 5.5 Nilai failure rate (473.RM1) ............................87
Tabel 5.6 Waktu antar Kegagalan (TBF)
Compressor (483.CP1) .................................... 89
Tabel 5.7 Hasil Pengujian TBF Roller Mill (473.RM1) .. 90
Tabel 5.8 Nilai Pdf dari Compressor (483.CP1) ............. 91
Tabel 5.9 Nilai Keandalan Compressor (483.CP1) ......... 93
Tabel 5.10 Nilai failure rate (483.CP1) ............................ 94
Tabel 5.11 Waktu antar Kegagalan (TBF)
Weight Feeder (483.WF1) ............................... 96
Tabel 5.12 Hasil Pengujian TBF
Weight Feeder (483.WF1) ............................... 97
Tabel 5.13 Nilai Pdf dari Weight Feeder (483.WF1)..........98
Tabel 5.14 Nilai Keandalan Weight Feeder (483.WF1) .... 99
Tabel 5.15 Nilai failure rate (483.WF1) ............................101
Tabel 5.16 Waktu antar Kegagalan (TBF)
Belt Conveyor (463.BC5) .................................102
Tabel 5.17 Hasil Pengujian TBF Belt Conveyor
(463.BC5) .........................................................103
Tabel 5.18 Nilai Pdf dari Belt Conveyor (463.BC5) ..........104
Tabel 5.19 Nilai Keandalan Belt Conveyor (463.BC5) ..... 106
Tabel 5.20 Nilai failure rate Belt Conveyor (463.BC5) .... 107
Tabel 5.21 Waktu antar Kegagalan (TBF)
Compressor (483.CP2) .....................................109
Tabel 5.22 Hasil Pengujian TBF Compressor (483.CP2) ..109
Tabel 5.23 Nilai Pdf dari Compressor (483.CP2) ..............110
Tabel 5.24 Nilai Keandalan Compressor (483.CP2) ..........112
Tabel 5.25 Nilai failure rate Compressor (483.CP2) .........114
Tabel 5.26 MTTR mesin Roller Mill (473.RM1) ...............116
Tabel 5.27 Hasil Pengujian Time Repair
Roller Mill (473.RM1) ..................................... 118
Tabel 5.28 Nilai MTTR dan MTBF
 Roller Mill (473.RM1) ..................................... 119
Tabel 5.29 MTTR mesin Compressor (483.CP1).............. 120
Tabel 5.30 Hasil Pengujian Time Repair
Compressor (483.CP1)..................................... 121
Tabel 5.31 Nilai MTTR dan MTBF
Compressor (483.CP1) .................................... 122
Tabel 5.32 MTTR mesin Weight Feeder (483.WF1) ........ 123
Tabel 5.33 Hasil Pengujian Time Repair
Weight Feeder (483.WF1) ............................... 124
Tabel 5.34 Nilai MTTR dan MTBF
Weight Feeder (473.WF1) ............................... 125
Tabel 5.35 MTTR mesin Belt Conveyor (463.BC5).......... 126
Tabel 5.36 Hasil Pengujian Time Repair
Belt Conveyor (463.BC5)................................. 127
Tabel 5.37 Nilai MTTR dan MTBF
Belt Conveyor (463.BC5) ................................ 128
Tabel 5.38 MTTR mesin Compressor (483.CP2) ..............129
Tabel 5.39 Hasil Pengujian Time Repair
Compressor (483.CP2) .................................... 129
Tabel 5.40 Nilai MTTR dan MTBF
Compressor (483.CP2) .................................... 131
Tabel 6.1 Fungsi Komponen-komponen Mesin
463.BC5 ........................................................... 140
Tabel 6.2 Fungsi Komponen-komponen Mesin
473.WF1 ...........................................................140
Tabel 6.3 Fungsi Komponen-komponen Mesin
473.RM1 .......................................................... 142
Tabel 6.4 Fungsi Komponen-komponen Mesin
483.CP1 ........................................................... 145
Tabel 6.5 Fungsi Primer dan Kegagalan Mesin
463.BC5 ........................................................... 148
Tabel 6.6 Fungsi Primer dan Kegagalan Mesin
473.WF1 .......................................................... 150
Tabel 6.7 Fungsi Primer dan Kegagalan Mesin
473.RM1 .......................................................... 151
Tabel 6.8 Fungsi Primer dan Kegagalan Mesin
483.CP1 ........................................................... 152
Tabel 6.9 Severity rating scale untuk mesin-mesin
Unit Coal Mill ..................................................153
Tabel 6.10 Occurance rating scale untuk mesin-mesin
Unit Coal Mill ..................................................154
Tabel 6.11 Detection rating scale untuk mesin-mesin
Unit Coal Mill ..................................................155
Tabel 6.12 Tabel Proporsi Tipe Kerusakan
Belt Conveyor ..................................................159
Tabel 6.13 Tabel Proporsi Tipe Kerusakan Chain .............161
Tabel 6.14 Tabel Proporsi Tipe Kerusakan
Roll Grinding ................................................... 162
Tabel 6.15 Tabel Proporsi Tipe Kerusakan Compressor ...164
Tabel 6.16 Tabel Failure Consequences ........................... 168
Tabel 6.17 Tabel Kriteria Technical Feasibility ................169
Tabel 6.18 Tabel Question Default Action ........................ 169
Tabel 6.19 Kondisi Pemilihan Kegiatan Perawatan .......... 170
Tabel 6.20 Interval Penjadwalan Perbaikan ...................... 172
Tabel 6.21 Interval Penjadwalan Penggantian ...................172
Tabel 6.22 Rekapitulasi Kebijakan Perawatan
Belt Conveyor ..................................................175
Tabel 6.23 Rekapitulasi Kebijakan Perawatan
Weight Feeder ..................................................175
Tabel 6.24 Rekapitulasi Kebijakan Perawatan
Roller Mill ....................................................... 175
Tabel 6.25 Rekapitulasi Kebijakan Perawatan
Compressor ...................................................... 175
 DAFTAR EQUIPMENT NUMBER

Plant Simbol Nama Mesin

463. Raw Coal
Handling 463.HP1 Hopper
463.AC1 Appron Conveyor
463.BC1 Belt Conveyor
463.BC2 Belt Conveyor
463.BC3 Belt Conveyor
463.TR1 Tripper
463.RR1 Reclaimer
463.BC4 Belt Conveyor
463.BC5 Belt Conveyor
463.BC6 Belt Conveyor
463.MD1 Metal Detector
463.MS1 Magnetic Separator
463.LM1 Level Monitor System
463.FB1 Feed Bin
473. Coal Grinding 473.WF1 Weight Feede
473.RM1 Roller Mill
473.EV1 Explosion Vent
473.EV2 Explosion Vent
473.BF1 Bag Filter
473.BF2 Bag Filter
473.SC1&2 Screw Conveyor
473.SC3&4 Screw Conveyor
473.RF1 Rotary Feeder
473.RF2 Rotary Feeder
473.SC5 Screw Conveyor
483. Pulverized Coal 483.BI2 Pulv Coal Bin
Feeding 483.LI1 Level Indikator
483.LM1 Level Monitor System
483.RF3 Rotary Feeder
483.SG1 Slide Gate
483.PP1&2 Pneumatic Pump
483.PP3&4 Pneumatic Pump
483.CP1 Compressor
483.CP2 Compressor
483.VA1 Valve
483.VA2 Valve
483.FB2 Feed Bin
483.SG2 Slide Gate
483.FB3 Feed Bin
483.SG3 Slide Gate
483.RF4 Rotary Feeder
483.RF5 Rotary Feeder
483.SG4 Slide Gate
483.SG5 Slide Gate
483.PW1 Pfister
483.PW2 Pfister
483.PW3 Pfister
483.BL1 Blower
483.BL2 Blower
483.BL3 Blower
 DAFTAR LAMPIRAN

Lampiran A-1 Data Histori Mesin

Lampiran B-1 Data Komponen V-Belt dan Seal Coal Mill
Lampiran C-1 Tabel Failure Mode And Effect Analysis
(FMEA)
Lampiran C-2 Fault Tree Analysis
Lampiran C-3 Decision Worksheet