TUGAS AKHIR

ANALISA TEAR DOWN REPORT DIESEL ENGINE

MODEL DE12TIA MENGGUNAKAN METODE SEVEN

TOOLS (PT KOBEXINDO TRACTORS TBK)

Diajukan Sebagai Syarat Untuk Mencapai Gelar Sarjana Teknik

Jurusan Teknik Mesin Fakultas Teknik

Universitas Muhammadiyah Surakarta

Disusun oleh :

MUSTOFA FARIS IZZUDDIN

NIM : D200140218

JURUSAN TEKNIK MESIN FAKULTAS TEKNIK

UNIVERSITAS MUHAMMADIYAH SURAKARTA

2018

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MOTTO

“Man Lam Yadzuq Murrot Ta’allumi Sa’atan, Tajarro’a Dzullal Jahli Thulal

Hayaatihi”

“Barang siapa belum pernah merasakan pahitnya (payahnya) menuntut ilmu

walau sesaat, Ia akan menelan hinanya kebodohan sepanjang hidupnya”

“Barangsiapa menyia-nyiakan waktu menuntut ilmu di masa mudanya, maka

bertakbirlah empat kali atas kematiannya.”

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ABSTRAKSI

Tear Down Report adalah format laporan yang diterapkan oleh PT

kobexindo Tractors untuk pekerjaan corrective maintenance & overhaul engine.

Di dalamnya memuat analisa kerusakan dan recommended part engine replace.

Dari hasil tear down report tersebut dilakukan analisa lanjutan menggunakan

metode seven tools dengan tujuan analisa untuk mengetahui jenis (NG) failure dan

cause of failure yang dominan terjadi. Selain itu, pada beberapa bagian dari

analisa tersebut juga memuat informasi mengenai komponen diesel engine yang

banyak terjadi kasus uncomplete, miss dan damage pada saat engine beroperasi.

Seven Tools adalah tujuh alat kendali mutu yang banyak digunakan untuk

analisa statistik di dalam dunia teknik industri. Penerapan metode seven tools

dapat digunakan pula di dalam dunia pendidikan, manajemen, ekonomi bisnis,

psikologi dll. Tujuannya adalah untuk perbaikan dan pengendalian kualitas .

Tujuh alat kendali mutu tersebut meliputi check sheet, stratifikasi, fish bone

diagram, pareto diagram, histogram, scatter diagram, dan control chart.

Hasilnya, dari analisa seven tools terhadap tear down report 24 engine

model DE12TIA yang dilakukan corrective maintenance dan overhaul, terdapat

16 jenis (NG) failure dengan angka worn (keausan) menjadi yang paling tinggi

yaitu sebanyak 70 kasus. Sedangkan untuk cause of failure terdapat 22 kasus

dengan bad lubricating menjadi yang paling tinggi sebanyak 86 kasus. Kemudian

Analisa scatter diagram untuk kasus prioritas yaitu worn sebagai variabel Y dan

bad lubricating sebagai variabel X menghasilkan korelasi posistif dengan nilai

korelasi r > 0 yaitu 0,95, ini berarti semakin tinggi angka bad lubricating maka

akan semakin tinggi pula angka Worn (keausan).

Kata Kunci :Tear Down Report, Failure, Cause Of Failure, Seven tools.

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ABSTRACT

Tear Down Report is a report format applied by PT Kobexindo Tractors

for corrective maintenance & overhaul engine work. In it contains damage

analysis and recommended replace engine parts. From the results of the tear

down report, further analysis is performed using the seven tools method with the

aim of analysis to determine the type of (NG) failure and the dominant cause of

failure. In addition, in some parts of the analysis also contains information about

diesel engine components that occur in many cases uncomplete, miss and damage

when the engine is operating.

Seven Tools are seven quality control tools that are widely used for

statistical analysis in the world of industrial engineering. The application of the

seven tools method can also be used in the world of education, management,

business economics, psychology etc. The aim is to improve and control quality.

The seven quality control tools include check sheets, stratification, fish bone

diagrams, pareto diagrams, histograms, scatter diagrams, and control charts.

As a result, from the seven tools analysis of the 24 engine DE12TIA model

tear down report which is corrective maintenance and overhaul, there were 16

types (NG) failure with the highest wear rate (70 cases). While for cause of failure

there were 22 cases with bad lubricating being the highest as many as 86 cases.

Then the scatter diagram analysis for priority cases is worn as variable Y and bad

lubricating as the X variable produces a positive correlation with the correlation

value r> 0 which is 0.95, this means that the higher the number of bad lubricating

the higher the number of Worn (wear).

Keywords: Tear Down Report, Failure, Cause Of Failure, Seven tools.

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KATA PENGANTAR

Assalamualaikum Wr,Wb

Syukur Alhamdulillah penulis panjatkan kehadirat Allah SWT atas berkah

dan rahmat-nya sehingga penyusunan laporan ini dapat terselesaikan. Tugas akhir

yang berjudul “ANALISA TEAR DOWN REPORT ENGINE DIESEL MODEL

DE12TIA MENGGUNAKAN METODE SEVEN TOOLS (PT KOBEXINDO

TRACTORS TBK)” dapat terselesaikan atas dukungan dari berbagai pihak.

Untuk itu, penulis pada kesempatan ini dengan ketulusan dan keiklasan hati yang

mendalam menyampaikan rasa terima kasih dan penghargaan besar kepada :

1. Bapak Ir. H Subroto, M.T selaku Ketua Jurusan Teknik Mesin Universitas

Muhammadiyah Surakarta.

2. Bapak Dr. Suranto selaku Direktur Sekolah Vokasi Universitas

Muhammadiyah Surakarta.

3. Bapak Amin Sulistyanto, S.T., M.T. selaku Dosen Pembimbing yang telah

banyak memberikan banyak ilmu, pengarahan, dan bimbingan kepada

penulis dalam menyelesaikan tugas ini.

4. Keluarga tercinta, bapak, ibu, dan adik yang selalu memberikan dukungan

dan doanya.

5. Teman-teman Teknik Mesin angkatan 2014 yang banyak memberi

semangat dan kebersamaannya.

6. Management PT Kobexindo Tractors Tbk, atas kesempatan yang

diberikan kepada penulis untuk menyelenggarakan penilitian ini.

7. Semua pihak yang telah membantu dalam penelitian dan penyusunan

laporan tugas akhir ini.

Didalam penyusunan/pembuatan laporan ini masih jauh dari kata

sempurna. Untuk itu, kritikan maupun saran yang bersifat membangun dengan

harapan pembuatan laporan selanjutnya dapat lebih baik. Semoga laporan ini

dapat berguna dan memberikan manfaat kedepannya.

Wassalamu’ailaikum Wr.Wb

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DAFTAR GAMBAR

Gambar 2. 1 Kurva Performance Engine ........................................ ................................6

Gambar 2.2 Letak Posisi Engine Number ..................................... ..................................6

Gambar 2.3 Engine Sectional View(Longitudinal) ............................. ............................7

Gambar 2.4 Engine Sectional View (Cross) ....................................... ........................... 8

Gambar 2.5 Engine Assembly Views ................................................... ......................... 9

Gambar 2.6 Engine View (Top) ......................................................... ...........................10

Gambar 2.7 Engine Mounting .............................................................. .........................10

Gambar 2.8 Cylinder Head .............................................................. .............................12

Gambar 2.9 Gambar Cylinder Head Cover ........................................ ...........................13

Gambar 2.10 Gambar Cylinder Block ................................................ ..........................15

Gambar 2.11 Gambar Pressure Gauge ...........................................................................16

Gambar 2.12 Driving System .........................................................................................21

Gambar 2.13 Fly Wheel Housing ....................................................... ...........................22

Gambar 2.14 Timing System ........................................................... .............................24

Gambar 2.15 Timing Gear Case ....................................................... .............................26

Gambar 2.16 Gambaran Umum Fuel System .................................... ...........................27

Gambar 2.17 Fuel System Engien DE12TIA ....................................... .........................28

Gambar 2.18 Fuel Pipe pada Fuel System Engine DE12TIA ............. ..........................30

Gambar 2.19 Fuel Filter pada Fuel System Engine DE12TIA ......... ............................31

Gambar 2.20 Injection Nozzle pada Fuel System Engine DE12TIA .... ........................31

Gambar 2.21 Fuel Pipe pada Fuel System Engine DE12TIA ................... ....................32

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Gambar 2.22 Injection Pump pada Fuel System Engine DE12TIA ........... ...................32

Gambar 2.23Injection Pump Drive ......................................................... ......................33

Gambar 2.24 Injection Pump Mounting .......................................................... ............. 34

Gambar 2.25 Engine Control ........................................................................... .............35

Gambar 2.26 Exhaust Manifold pada Exhaust System Engine DE12TIA ...... ............. 36

Gambar 2.27 Intake Manifold pada Intake System Engine DE12TIA ..... ...................37

Gambar 2.28 Intake Stake ........................................................................... ......... ....... 38

Gambar 2.29 Turbo Charger pada Engine DE12TIA .................................. .................38

Gambar 2.30 Breather................................................................................... ............... 40

Gambar 2.31 Gambaran Umum Lubrication System ................................. .................. 41

Gambar 2.32 Oil Pump pada Engine DE12TIA ........................................... ............... 42

Gambar 2.33 Oil Filter pada Lubricating System Engine DE12TIA ............ ............... 43

Gambar 2.34 Oil Pan pada Lubricating System Engine DE12TIA ............ ..................44

Gambar 2.35 Gambaran Umum Cooling system Engine DE12TIA ............ ................ 46

Gambar 2.36 Thermostat pada Engine DE12TIA ........................................ ................ 47

Gambar 2.37 Sketsa Mekanisme Thermostat ................................................ ............... 47

Gambar 2.38 Cooling Water Pipe Pada Cooling System Engine DE12TIA . ...............48

Gambar 2.39 Water Pump pada Cooling System Engine DE12TIA ............. ...............50

Gambar 2.40 Oil Cooler pada Cooling System Engine DE12TIA ................. ..............51

Gambar 2.41 Cooling Fan pada Cooling System Engine DE12TIA ............. ...............52

Gambar 2.42 Starter pada Electric System Engine DE12TIA...................... ............... 54

Gambar 2.43 Alternator pada Engine DE12TIA ......................................... ................. 54

Gambar 2.44 Alternator Mounting Pada Alternator Engine DE12TIA .......... ............. 55

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Gambar 2.45 Electric Control Unit Pada Electrical System .................. ...................... 56

Gambar 2.46 Electric Ignition System pada Electrical System .............. ..................... 56

Gambar 2.47 Power Steering Pump ......................................................... .................... 57

Gambar 2.48Air Compressor ..................................................................... .................. 58

Gambar 2.49Air Conditioner ........................................................................... ............ 60

Gambar 2.50 Accessory Part Engine DE12TIA ............................................................62

Gambar 3.1 Sketsa Pola Histogram Distribusi Normal .................... ............................ 77

Gambar 3.2 Kurva Normal Distribution .............................................. .........................77

Gambar 3.3 Sketsa Pola Histogram Skewed Distribution ................... .........................78

Gambar 3.4 Sketsa Pola Histogram Bimodal Distribution ................. ..........................78

Gambar 3.5 Sketsa Pola Histogram Nilai Data Tersebar Rata ............. .........................79

Gambar 3.6 Jenis-Jenis Korelasi Antara Dua Variabel ......................... ........................80

Gambar 3.7 Contoh /Gambaran Umum Diagram Fish Bone ................ ....................... 83

Gambar 3.8 Contoh X Chart ................................................................... ......................86

Gambar 3.9 Flow Chart Overhaul & TDR Engine.................................... .................. 89

Gambar 4.1 Grafik Stratifikasi Failure Terhadap Masing Masing Engine ….........….. 98

Gambar 4.2 Diagram Fish Bone Analisa Damage Tear Down Report Engine….........101

Gambar 4.3Diagram Pareto Jenis Failure Tear Down Report Engine Pada

Analisa Damage Tear Down Report Engine DE12TIA .................. ............................104

Gambar 4.4 Diagram Pareto Cause Of Failure Pada Analisa Damage Tear

Down Report Engine DE12TIA ................................................ ..................................105

Gambar 4.5 Histogram Type Of Failure Pada Analisa Damage Tear Down

Report Engine DE12TIA .......................................................... .................................. 106

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Gambar 4.6 Histogram Cause Of Failure Pada Analisa Damage Tear Down

Report Engine DE12TIA ............................................................................. ............... 107

Gambar 4.7 Diagram Scatter Bad Lubricating Terhadap Worn (Keausan) ............... 108

Gambar 4.8 Diagram Scatter Fatique Terhadap Worn (Keausan)............. ..................110

Gambar 4.9 Diagram Scatter Fatique Terhadap NG Broken ……….........……..…... 111

Gambar 4.10 Grafik Peta Keseluruhan Failure Pada Analisa Damage Tear

Down Report Engine DE12TIA ............................................... ................... .. 113

Gambar 4.11 Grafik Peta Kendali Worn (Keausan) Pada Analisa Damage Tear

Down Report Engine DE12TIA ............................................... ..................... .115

Gambar 4.12 Grafik Peta Kendali NG Broken Pada Analisa Damage Tear

Down Report Engine DE12TIA ................................................ ......................117

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DAFTAR TABEL

Tabel 2.1 General Spesifications Engine DE12TIA ................................. ......................5

Tabel 2.2 Engine Performance Between DE12TI & DE12TIS / TIA ........ .................... 5

Tabel 2.3 Bagian Bagian Engine Mounting ................................................. ................ 10

Tabel 2.4 Bagian Bagian Cylinder Head ..................................................... ................. 12

Tabel 2.5 Bagian Bagian Cylinder Head Cover ....................................... .................... 13

Tabel 2.6 Bagian Bagian Cylinder Block ................................................ .....................15

Tabel 2.7 Bagian Bagian Pressure Gauge ................................................ .....................16

Tabel 2.8 Bagian Bagian Driving System ................................................. ................... 19

Tabel 2.9 Bagian Bagian Fly Wheel Housing ............................................. ................. 21

Tabel 2.10 Bagian Bagian Timing System .................................................... ...............24

Tabel 2.11 Bagian Bagian Timing Gear Case ........................................ .......................26

Tabel 2.12 Bagian Bagian Fuel System Engine DE12TIA ..................... ..................... 29

Tabel 2.13 Bagian Bagian Fuel Pipe pada Fuel System Engine DE12TIA ... .............. 30

Tabel 2.14 Bagian Bagian Fuel Filter pada Fuel System Engine DE12TIA ... .............31

Tabel 2.15 Bagian² Injection Nozzle pada Fuel System Engine DE12TIA ..... ........... 32

Tabel 2.16 Bagian² Fuel Pipe pada Fuel System Engine DE12TIA.............. ............... 32

Tabel 2.17 Bagian² Injection Pump pada Fuel System Engine DE12TIA ......... .......... 33

Tabel 2.18 Bagian Bagian Injection Pump Drive ...................................... ...................33

Tabel 2.19 Bagian Bagian Injection Pump Mounting ............................... ....................34

Tabel 2.20 Bagian Bagian Engine Control ................................................ ...................35

Tabel 2.21 Bagian² Exhaust Manifold pada Exhaust System .................. .....................36

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Tabel 2.22 Bagian² Intake Manifold pada Intake System ............................ ................ 37

Tabel 2.23 Bagian Bagian Intake Stake........................................................ ................ 38

Tabel 2.24 Bagian Bagian Turbo Charger pada Engine DE12TIA .............. ................39

Tabel 2.25 Bagian Bagian Breather .............................................................. ................39

Tabel 2.26 Recommended Oil ...................................................................... ................ 41

Tabel 2.27 Engine Oil Capacity ..................................................................... .............. 42

Tabel 2.28 Bagian Bagian Oil Pump Engine DE12TIA ................................. ..............42

Tabel 2.29 Bagian² Oil Filter pada Lubricating System Engine DE12TIA ...... ............43

Tabel 2.30 Bagian² Oil Pan pada Lubricating System Engine DE12TIA ....... ..............44

Tabel 2.31 Bagian Bagian Thermostat......................................................... ............…..47

Tabel 2.32 Thermostat Type ........................................................................ .................48

Tabel 2.33 Bagian² Cooling Water Pipe Pada Cooling System ............... .....................48

Tabel 2.34 Bagian² Water Pump pada Cooling System ............................. ...................50

Tabel 2.35 Bagian ² Oil Cooler pada Cooling System ................................. .................51

Tabel 2.36 Bagian² Cooling Fan pada Cooling System ............................. ...................53

Tabel 2.37 Coolant Volume……………………………................................................53

Tabel 2.38 Bagian² Starter pada Electric System ....................................... .................. 54

Tabel 2.39 Bagian² Alternator pada Engine DE12TIA ............................... ..................55

Tabel 2.40 Bagian² Alternator Mounting Pada Alternator .................... ....................... 55

Tabel 2.41 Bagian² Electric Control Unit Pada Electrical System ................. ..............56

Tabel 2.42 Bagian² Electric Ignition System pada Electrical System ........... ................57

Tabel 2.43 Bagian Bagian Power Steering Pump.......................................... ................58

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Tabel 2.45 Bagian Bagian Air Compressor .......................................... ........................59

Tabel 2.46 Bagian Bagian Air Conditioner ........................................... ........................61

Tabel 2.47 Bagian Bagian Accessory Part Engine DE12TIA ................ ...................... 61

Tabel 4.1 Data Engine RFU Selama Periode 2014 -2018 ......................... ................... 92

Tabel 4.2 Data Engine DE12TIA Periode 2014 – 2015 ............................. ................. 92

Tabel 4.3 Summary Uncomplete Komponen Tear Down Report Engine......... ........... 93

Tabel 4.4 Summary Miss Component ......................................... ................................. 95

Tabel4.5 Summary Damage Component ..................................... ................................ 96

Tabel 4.6 Stratifikasi Failure Terhadap Masing Masing Engine

DE12TIA 322536EC. ................................................................................. ...................98

Tabel 4.7 Stratifikasi Responsible Terhadap Cause Of Failure.................... ................ 99

Tabel 4.8 Sampel Tabel Analisa Damage pada Tear Down Report Engine….........…100

Tabel 4.9Data Hasil Perhitungan 10 Failure (NG) Terbesar Pada Analisa

Damage Tear Down Report Engine DE12TIA.............................................. ............ 104

Tabel 4.10 Data Hasil Penelitian 10 Cause Of Failure Terbesar Pada Analisa

Damage Tear Down Report Engine DE12TIA......................................... ...................105

Tabel 4.11 Data Hasil Pengamatan Bad Lubricating Terhadap Worn ….........……... 108

Tabel 4.12 Data Hasil Pengamatan Fatique Terhadap Worn ………..…….........…... 109

Tabel 4.13 Data Hasil Pengamatan Fatique Terhadap NG Broken … ….........……...110

Tabel 4.14 Data untuk np Chart Seluruh Failure, Ukuran Sampel n = 827 ..... ..........112

Tabel 4.15 Data untuk np Chart Worn (Keausan), Ukuran Sampel n = 827 ... ...........114

Tabel 4.16 Data Untuk np NG Broken Ukuran Sampel n = 827 …………..……….. 116