Analisis Keandalan dan Penjadwalan Pemeliharaan Mesin Line Corrugated dan Flexo Serta Optimasi Persediaan Sparepart di Perusahahan Pembuatan Karton Box

Nurdianto, Donny (2025) Analisis Keandalan dan Penjadwalan Pemeliharaan Mesin Line Corrugated dan Flexo Serta Optimasi Persediaan Sparepart di Perusahahan Pembuatan Karton Box. Undergraduate thesis, Universitas 17 Agustus 1945 Surabaya.

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Abstract

Penelitian ini bertujuan untuk menganalisis keandalan komponen mesin line corrugated dan mesin flexo, menyusun penjadwalan preventive maintenance, serta menentukan Reorder Point (ROP) untuk sparepart kritis pada perusahaan manufaktur karton box di Gresik. Permasalahan utama dalam proses produksi adalah tingginya downtime mesin akibat dominasi corrective maintenance dan belum optimalnya pengelolaan persediaan sparepart yang menyebabkan keterlambatan perbaikan dan gangguan kontinuitas produksi.Penelitian menggunakan data historis kerusakan selama 1,5 tahun (Januari 2024 sampai Juni 2025), meliputi durasi downtime, frekuensi perbaikan, dan kebutuhan sparepart. Analisis keandalan dilakukan melalui perhitungan Mean Time To Failure (MTTF), Mean Time To Repair (MTTR), dan Mean Time Between Failures (MTBF), disertai penentuan distribusi probabilitas (Weibull, eksponensial, lognormal, dan normal) untuk memperoleh nilai reliabilitas pada interval waktu tertentu. Hasil perhitungan tersebut digunakan untuk menyusun interval preventive maintenance yang optimal. Selain itu, perhitungan ROP dilakukan berdasarkan rata-rata pemakaian, lead time, dan safety stock untuk menentukan kebutuhan persediaan suku cadang secara akurat.Hasil penelitian menunjukkan bahwa tingkat keandalan sebagian besar komponen pada kedua jenis mesin berada pada kategori rendah, dengan nilai reliabilitas berkisar antara 2 persen hingga 66 persen, bergantung pada distribusi kegagalan masing-masing komponen. Mesin corrugated merupakan mesin dengan frekuensi kerusakan tertinggi, terutama pada komponen rotating, transmisi, dan sistem pelumasan. Pada mesin flexo, komponen seperti as setelan, ulir slotter, bearing oneway, rubber roll, dan coupling kuningan menjadi sumber gangguan utama. Sementara itu, perhitungan ROP menunjukkan bahwa sebagian besar komponen membutuhkan stok 2 sampai 3 unit, namun beberapa komponen kritis seperti as setelan (ROP 4) dan membran pompa (ROP 9) memiliki kebutuhan jauh lebih tinggi karena frekuensi kerusakannya yang besar.

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