ABSTRACT

PURBA, KASPAR, Trisakti University, July 2013, The Effect of Implementation of Filter Parallel Box on Productivity, Yield & Energy Consumption in PT. Tembaga Mulia Semanan, Tbk.

Major Advisor : Prof. Dr. Syamsir Abduh

The background of this research was due to high production downtime in process line – 1 regarding changing filter. It made downtime about 2 hours. Change filter is done because filter was stuck by inclusion such as Al2O3; MgO; MgAl2O4; Al4C3; TiB2; AlB2, etc after running several hours. System filter was series type. It means that if one of filter was stuck by inclusion, it must change all filter in filter box. This change filter period will disturb our productivity, yield and also energy consumption.

The objective of this research was to change filter without disturb our production (no downtime). Change filter is a vital action to keep level quality of molten aluminum. The cleaner of molten aluminum, the quality of aluminum rod will be increase (reduce wire break at drawing process).

The idea of this action is to modify filtration system, from system filter series become system filter parallel. This parallel type will not disturb our process because if one filter was stuck, another filter standby will change the stuck one without disturb our process.

To analyze the effectiveness of filter parallel box, variable productivity, yield and energy consumption will analyze by three difference methods, they are descriptive statistic (to analyze means), paired samples t-test (to analyze significant degree) and statistical process control (to analyze variation of process).

The result of this research conclude that filter parallel box increased productivity from 2,25 ton/hour become 2,37 ton/hour (increased 0,125 ton/hour). Yield increased from 96,73 % become 98,23 % (increased 1,50 %). Energy consumption reduced from 171,62 m3/ton become 149,82 m3/ton (reduced 21,80 m3/ton). This result makes our process become more efficiency and more effective to reduce cost production.