ANALISIS PENERAPAN LEAN MAINTENANCE UNTUK OPTIMALISASI DURASI OVERHAUL TURBINE INSPECTION (TI) DI PERUSAHAAN OPERATION & MAINTENANCE PEMBANGKIT LISTRIK PT IP

DUTO, YOPPY SETYO (2023) ANALISIS PENERAPAN LEAN MAINTENANCE UNTUK OPTIMALISASI DURASI OVERHAUL TURBINE INSPECTION (TI) DI PERUSAHAAN OPERATION & MAINTENANCE PEMBANGKIT LISTRIK PT IP. S2 thesis, Universitas Mercu Buana Jakarta.

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Abstract

The increase in the number of national electricity customers which is increasing every year must be followed by the availability of sufficient supply of electrical energy from power plants so that there is no energy deficit. Maintenance and overhaul activities are carried out routinely on the generator's main equipment so that it continues to be reliable and efficient. Turbine Inspection (TI) overhaul activity at a Gas Turbine Combined Cycle Power Plant is a type of periodic inspection activity carried out at the power unit operated by PT IP. Data on the history of TI overhaul implementation during the 2016 - 2021 period shows that there was a delay in completing the overhaul which resulted in a sizable loss of production opportunity. Identification of the causes of waste (waste) is carried out using a lean approach with a combination of the use of Root Cause Failure Analysis (Fishbone, Why Analysis and 5W+1H) and Value Stream Mapping (VSM) tools. The primary data in this study is the result of direct field observations and interviews with experts. Secondary data comes from previous TI overhaul implementation history data. The results of data analysis are used to make Current State Mapping (CSM) including the potential for existing waste. Decreasing the duration of TI overhaul is more focused on Critical Path activities which have elements of waste and have a significant influence on the total duration of TI overhaul work. Activity identification falls into the Non-Value Added (NVA) category, and Necessary Non-Value Added (NNVA) is used as the basis for making Future State Mapping including corrective steps that must be taken to optimize the overhaul duration to be used in the next OH TI. The total duration of the next TI overhaul, namely GT 4.2 TI 2022 after the implementation of the FSM and all improvement steps that have been made, is close to the standard duration given by the manufacturer, which is 22 days. Keyword: Turbine Inspection (TI), loss production opportunity, Waste, Lean, Value Stream Mapping Peningkatan jumlah pelanggan listrik nasional yang semakin meningkat setiap tahun harus diikuti dengan ketersediaan pasokan energi listrik dari pembangkit listrik yang cukup agar tidak terjadi defisit energi. Kegiatan maintenance dan overhaul yang dilakukan secara rutin pada peralatan utama pembangkit agar terus handal dan efisien. Kegiatan overhaul Turbine Inspection (TI) pada sebuah Pembangkit Listrik Tenaga Gas Uap (PLTGU) merupakan salah jenis kegiatan periodical inspection yang dilakukan di unit pembangkit yang dioperasikan oleh PT IP. Data history pelaksanaan overhaul TI selama periode 2016 - 2021 menunjukan adanya keterlambatan penyelesaian overhaul yang mengakibatkan terjadinya loss production opportunity yang cukup besar. Identifikasi penyebab waste (pemborosan) dilakukan menggunakan pendekatan Lean dengan kombinasi penggunaan tools Root Cause Failure Analysis (Fishbone, Why Analysis dan 5W+1H) dan Value Stream Mapping (VSM). Data primer pada penelitian ini merupakan hasil observasi langsung di lapangan dan wawancara dengan para expert. Data sekunder berasal dari data history pelaksanaan overhaul TI sebelumnya. Hasil analisis data digunakan untuk pembuatan Current State Mapping (CSM) termasuk potensi waste yang ada. Penurunan durasi overhaul TI lebih difokuskan pada Critical Path aktivitas yang mempunyai unsur waste dan memiliki pengaruh signifikan terhadap total durasi pekerjaan overhaul TI. Identifikasi aktivitas masuk ke dalam kategori Non-Value Added (NVA), dan Necessary Non-Value Added (NNVA) digunakan sebagai dasar pembuatan Future State Mapping termasuk langkah perbaikan yang harus dilakukan untuk optimalisasi durasi overhaul yang akan digunakan pada OH TI selanjutnya. Total durasi overhaul TI selanjutnya yaitu GT 4.2 TI 2022 setelah dilakukan implementasi FSM dan semua langkah perbaikan yang sudah dibuat mendekati durasi standar yang diberikan oleh pihak manufaktur yaitu 22 hari. Kata Kunci: Turbine Inspection (TI), loss production opportunity, Waste, Lean, Value Stream Mapping (VSM).

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