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PERANCANGAN ULANG POSTUR KERJA
MEGGUNAKAN METODE OCCUPATIONAL
REPETITIVE ACTION (OCRA) INDEX DI PROSES
PACKAGING PUPUK ZA
Skripsi
Diajukan Kepada Universitas Muhammadiyah Malang
Untuk Memenuhi Salah Satu Persyaratan Akademik
Dalam Menyelesaikan Program Sarjana Teknik
Disusun Oleh:
DICKY OKTO RIANDAKA
201510140311016
JURUSAN TEKNIK INDUSTRI
FAKULTAS TEKNIK
UNIVERSITAS MUHAMMADIYAH MALANG
2020
v
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vii
KATA PENGANTAR Assalamualaikum Wr. Wb.
Alhamdulillah, puji syukur atas kehadirat Allah SWT karena berkat Rahmat,
Berkah dan Karunia-Nya penulis dapat menyelesaikan penyusuan skripsi ini. Shalawat
serta salam semoga senantiasa terlimpah kepada Nabi Muhammad SAW yang telah
menjadi panutan sehingga penulis dapat menyelesaikan skripsi yang berjudul
“Perancangan Ulang Postur Kerja Menggunakan Metode Occupational Repetitive
Action (OCRA) Index di Proses Packaging Pupuk ZA”. Penulisan skripsi ini
diajukan untuk memenuhi salah satu persyaratan akademik memperoleh gelar Sarjana
pada jurusan Teknik Industri Fakultas Teknik Universitas Muhammadiyah Malang.
Selama penyusunan skripsi tidak terlepas dari bantuan, bimbingan, dan
motivasi dari berbagai pihak. Untuk itu kesempatan ini penulis dengan senang hati
menyampaikan terima kasih kepada yang terhormat:
1. Allah SWT, atas segala tuntunan, kesehatan, kemudahan, kekuatan, dan
keselamatan yang diberikan kepada penulis selama pengerjaan skripsi.
2. Kedua Orang Tua tercinta, Ibu Kustinah serta Bapak Rianto yang selalu
memberikan semangat, dukungan, serta doa untuk anaknya hingga sampai pada
titik ini, dan juga seluruh keluarga dirumah maupun di malang yang selalu
memberikan doa dalam pengerjaan skripsi ini.
3. Bapak Teguh Baroto, S.T., M.T. sebagai Dosen Pembimbing I yang memberikan
waktu, tenaga, serta bimbingan dan motivasi untuk menyelesaikan skripsi ini.
Terimakasih untuk ilmu bermanfaat yang ibu berikan,. Semoga Bapak dan
keluarga sehat selalu dan diberikan rezeki yang berlimpah, aamiin.
4. Bapak Ir Heri Mujayin Kholik, S.T., M.T. sebagai Dosen Pembimbing II. Terima
kasih atas segala bimbingan, ajaran, dan ilmu selama penyusunan skripsi serta
ketika menjadi salah satu asisten ibu. Mohon maaf apabila ada perilaku dan ucapan
viii
saya yang kurang berkenan. Semoga bapak dan keluarga sehat selalu dan diberikan
rezeki yang berlimpah, aamiin.
5. Bapak Ilyas Masudin, S.T., M. Log.Scm, PhD., selaku Ketua Jurusan.
6. Bapak/Ibu Dosen dan Staff jurusan Teknik Industri yang telah banyak membantu
dalam penyelesaian skripsi ini serta memberikan petuah-petuah kehidupan saat
dalam perkuliahan.
7. Saudari Ainun dwi fridayati yang telah membantu dalam pengerjaan skripsi ini.
8. Tim Playrit, Alap-alap krekah, HCKP Crew yang selalu memberikan dukungan
dalam pengerjaan skripsi.
9. Dulur-dulur kontrakan Jahanam yang sedari awal masuk sampai selesai kuliah
selalu menjadi support system dalam segala macam kondisi, Edwin yang IQ diatas
rata-rata seindustri 2015, Giant (baser) penguasa sound system pesisir utara ,
Caesar king of ngeue, Yunus yang bisa dalam segala hal,adit susah seneng mlaku
bareng. Hendi bisnisman tour and travel, dan sobat kontrakan yang tidak bisa saya
sebutkan satu persatu.
10. Rekan-rekan Teknik Industri, khusunya angkatan 2015 A, tempat pertama
mengenal namanya bangku kuliah. Semoga semua cita-cita kalian tercapai.
11. Semua pihak yang tidak dapat disebutkan satu persatu, terimakasih atas doa yang
kalian panjatkan. Semoga yang diperjuangkan saat ini menjadi berkah.
Akhir kata, Rasa hormat dan terimakasih bagi semua pihak atas segala dukungan dan
doanya. Penulis hanya dapat menghaturkan doa kepada Allah SWT semoga segala
perhatian, bantuan, dukungan, semangat serta motivasi, semoga Allah SWT membalas
segala kebaikan mereka berikan kepada penulis. Aamiin.
Wassalamualaikum Wr. Wb.
Malang, 11 Februari 2020
Penulis
DICKY OKTO RIANDAKA
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Daftar Isi
Halaman Judul.............................................................................................................................
Lembar Pengesahan..................................................................................................................
Lembar Asistensi Skripsi.............................................................................................................
Berita Acara Ujian.......................................................................................................................
Surat Pernyataan Keaslian..........................................................................................................
Surat Keterangan Penelitian.......................................................................................................
Form Cek Plagiasi........................................................................................................................
Kata Pengantar..........................................................................................................................i
Abstrak.....................................................................................................................................iii
Abstract....................................................................................................................................iv
Daftar Isi....................................................................................................................................v
Daftar Tabel........................................................................................................................... viii
Daftar Gambar............................................................................................................................x
BAB I PENDAHULUAN ........................................................................................................1
1.1 Latar Belakang .........................................................................................................2
1.2 Rumusan Masalah ....................................................................................................2
1.3 Tujuan Penelitian......................................................................................................2
1.4 Manfaat Penelitian....................................................................................................3
1.5 Batasan Masalah .......................................................................................................3
BAB II LANDASAN TEORI ..................................................................................................4
2.1 Sejarah Ocra .............................................................................................................4
2.2 Nordic Body Map......................................................................................................4
2.3 OCRA .......................................................................................................................5
2.3.1 Penentuan Ocra index ..............................................................................................7
2.3.3.1 Tindakan teknis ATA ...........................................................................................7
2.3.1.2 Tindakan teknis RTA ...........................................................................................9
2.3.2 Klasifikasi hasil OCRA index................................................................................ 19
2.3.3 Peta tangan kiri dan tangan kanan ......................................................................... 21
2.3.3.1 Kegunaan peta tangan kanan dan tangan kiri ..................................................... 21
BAB III METODOLOGI PENELITIAN ............................................................................... 22
3.1 Metodelogi penelitihan ..........................................................................................22
3.2 Tahap penelitihan ...................................................................................................22
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3.3 Tahap pengumpulan data ........................................................................................ 25
3.4 Tahap pengelolahan datal ............................................................................................ 26
3.5 Tahap analisa dan pembahasan ..................................................................................29
3.6 Kesimpulan dan saran ................................................................................................. 29
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA .................................................. 30
4.1 Tinjauan Perusahaan ..............................................................................................30
4.1.1 Profil PT Petro kimia ...............................................................................................30
4.1.2 Visi dan misi perusahaan .........................................................................................30
4.1.3 Alur proses pembuatan pupuk ZA ............................................................................31
4.1.4 Struktur organisasi .................................................................................................33
4.2 Pengumpulan data ....................................................................................................35
4.2.1 Operator pengantongan ..........................................................................................36
4.2.2 Operator penjahitan ...............................................................................................38
4.2.3 Loader ...................................................................................................................39
4.3 Perhitungan OCRA...................................................................................................... 41
4.3.1 Operator pengantongan ...........................................................................................41
4.3.1.1 Penentuan Actual Tecnical Actions ......................................................................41
4.3.1.2 Penentuan RTA .....................................................................................................42
4.2.1.3 Penentuan OCRA index ........................................................................................57
4.2.1.4 Klasifikasi hasil OCRA .........................................................................................57
4.3.2 Operator penjahitan ..................................................................................................57
4.3.2.1 Penentuan ATA .....................................................................................................57
4.3.2.2 Penentuan Recomended technical actions (RTA) .................................................58
4.3.2.3 Penentuan OCRA index .......................................................................................69
4.3.2.4 Klasifikasi hasil OCRA index ...............................................................................69
4.3.3 Loader ......................................................................................................................69
4.3.3.1 Penentuan Actual Technical Actions (ATA) .........................................................69
4.2.3.2 Penentuan Recomended technical actions (RTA) ..................................................70
4.3.3.3 Penentuan OCRA index ........................................................................................80
4.3.3.4 Klasifikasi hasil OCRA index ...............................................................................80
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BAB V ANALISA DAN PEMBAHASAN ........................................................................... 81
5.1 Analisa perbaikan metode kerja .............................................................................81
5.1.1 Periode pemulihan ...................................................................................................81
5.3 Analisa perbaikan postur kerja ...............................................................................84
5.3.1 Analisa perbaikan durasi ..........................................................................................89
5.3.2 analisa resiko tambahan ........................................................................................... 90
5.4 Analisa perhitungan OCRA setelah perbaikan ............................................................90
5.4.1 Actual Technical action (ATA) ................................................................................90
5.4.2 Analisa RTA ............................................................................................................91
5.4.3 Analisa faktor kekuatan ............................................................................................91
5.4.4 Analisa faktor stereotypy .........................................................................................92
5.4.5 Analisa faktor durasi ...............................................................................................92
5.4.6 Analisa faktor resiko tambahan ...............................................................................92
5.4.7 Analisa faktor periode pemulihan ............................................................................93
5.4.8 Analisa postur janggal ..............................................................................................93
5.5 Penentuan OCRA index .........................................................................................108
5.6 Klasifikasi ocra index .............................................................................................108
BAB VI KESIMPULAN DAN SARAN .............................................................................. 111
6.1 Kesimpulan ..........................................................................................................111
6.2 Saran ....................................................................................................................112
Daftar Pustaka ...................................................................................................................... 113
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Daftar Tabel
Tabel 2.1 Skala CR-10 Borg dan Faktor Kekuatan ............................................................... 10
Tabel 2.2 Skala Cr 10 Borg ................................................................................................... 10
Tabel 2.3 skor gerakan bahu .............................................................................................. 11
Tabel 2.4 skor gerakan siku................................................................................................. 13
Tabel 2.5 skor gerakan pergelangan tangan ........................................................................ 14
Tabel 2.6 skor gerakan genggaman .....................................................................................15
Tabel 2.7 faktor postur ..........................................................................................................16
Tabel 2.8 skor steoretpy ........................................................................................................17
Tabel 2.9 skor risiko berdasrkan rasio waktu ........................................................................18
Tabel 2. 10 tabel nilai risiko kekurangan...............................................................................18
Tabel 2. 11 skor tambahan ....................................................................................................19
Tabel 2.12 keterangan faktor pengal ......................................................................................19
Tabel 2.13 durasi pekerjaan repetitive ...................................................................................19
Tabel 2.14. klasifikasi hasil ocra index.................. ................................................................20
Tabel 3.1 klasifikasi hasil ocra index .....................................................................................28
Tabel 4.1 Profil perusahaan ...................................................................................................30
Tabel 4.2 tabel distribusi jam kerja dan jam istirahat pada unit pengantongan ..................... 35
Tabel 4.3 durasi kerja Pengunit pengantongan ......................................................................36
Tabel 4.4 kegiatan pengantongan ...........................................................................................37
Tabel 4.5 kegiatan penjahitan.................................................................................................39
Tabel 4.6kegiatan loading pupuk ..........................................................................................40
Tabel 4.7tindakan teknis dalam 1 siklus operator pengantongan ...........................................41
Tabel 4.8 skala cr 10 borg tangan kanan operator pengantongan ...........................................43
Tabel 4.9 skala cr 10 borg tangan kiri operator pengantongan..............................................44
Tabel 4.10 penilaian postur tangan kanan operator pengantonngan ......................................48
Tabel 4.11 penilaian postur tangan kiri operator pengantonngan............................................49
Tabel 4.12 tabel distribusi jam kerja dan jam istirahat ...........................................................51
Tabel 4.13 Tabel waktu kerja dan istirahat aktual ..................................................................51
Tabel 4.14 penentuan risiko kurangnya waktu pemuliahan.....................................................53
Tabel 4.15 faktor tamabahan tangan kanan proses pengantongan.......................................... 54
Tabel 4.16 faktor pengali RTA............................................................................................... 55
Tabel 4.17 faktor rekapan RTA ............................................................................................ .55
Tabel 4.18 tindakan teknis operator penjahitan.................................................................. ...57
Tabel 4.19 skala cr 10 borg tangan kanan operator penjahitan...............................................59
Tabel 4.20 skala cr 10 borg tangan kiri operator penjahitan..................................................60
Tabel 4.21 penilaian postur tangan kanan operator penjahitan..............................................64
Tabel 4.22 penilaian postur tangan kiri operator penjahitan .................................................65
xiii
Tabel 4.23faktor tamabahan tangan kanan proses penjahitan............................................. ..66
Tabel 4.24 faktor pengali RTA...............................................................................................67
Tabel 4.25 faktor rekapan RTA .............................................................................................68
Tabel 4.26 tindakan teknis loader.................................................................. ......................70
Tabel 4.27 skala cr 10 borg tangan kanan loader.....................................................................71
Tabel 4.28 skala cr 10 borg tangan kiri loader.........................................................................72
Tabel 4.29 penilaian postur tangan kanan operator penjahitan.............................................. 75
Tabel 4.30 penilaian postur tangan kiri operator penjahitan ..................................................76
Tabel 4.31 faktor pengali RTA.................................................................................................78
Tabel 4.32 faktor rekapan RTA ...............................................................................................79
Tabel 5.2 Perabaikan faktor durasi ........................................................................................89
Tabel 5.3. nilai ATA ...............................................................................................................91
Tabel 5.4 Perabaikan faktor durasi ........................................................................................92
Tabel 5.5 Penilaian postur tangan kanan operator pengantongan setelah perbaikan...............96
Tabel 5.6 Penilaian postur tangan kiri operator pengantongan setelah perbaikan..................97
Tabel 5.7 Penilaian postur tangan kanan operator penjahitan setelah perbaikan..................101
Tabel 5.8 Penilaian postur tangan kiri operator penjahitan setelah perbaikan......................102
Tabel 5.9 Penilaian postur tangan kanan loader setelah perbaikan......................................105
Tabel 5.10 Penilaian postur tangan kiri loader setelah perbaikan.......................................106
Tabel 5.11. nilai RTA setelah perbaiakan..............................................................................107
Tabel 5.12. klasifiakasi OCRA index setelah perbaikan ....................................................108
xiv
Daftar Gambar
Gambar 2.1 nordic body map ..................................................................................................5
Gambar 2.2 arm flextion ....................................................................................................... 11
Gambar 2.3 arm abduction ..................................................................................................... 11
Gambar 2.4 arm extencion ..................................................................................................... 11
Gambar 2.5 elbow .................................................................................................................. 12
Gambar 2.7 elbow extencion ..................................................................................................12
Gambar 2.9 genggaman tangan ..............................................................................................14
Gambar 2.10 pinch .................................................................................................................15
Gambar 2.11 palmar grip .......................................................................................................15
Gambar 2.7 elbow extencion ..................................................................................................12
Gambar 2.9 genggaman tangan ..............................................................................................14
Gambar 3.1 flowchart penelitian ............................................................................................24
Gambar 4.1 alur produksi .......................................................................................................31
Gambar 4.2 struktur organisasi .............................................................................................33
Gambar 4.3 operator pengantongan mengarahkan karung ke mesin ....................................45
Gambar 4.4 operator penjahitan meraih karung ....................................................................61
Gambar 4.5 loader meraih karung ..........................................................................................73
Gambar 5.1 denah unit pengantongan ..................................................................................81
Gambar 5.2 diagram waktu kerja aktual operator pengantongan ,penjahitan loader ............82
Gambar 5.3 usulan metode kerja ...........................................................................................83
Gambar 5.4 posisi genggaman sebelum perbaikan .................................................................84
Gambar 5.5 posisi genggaman usulan operator pengantongan ............................................84
Gambar 5.7 posisi genggaman sebelum perbaikan ................................................................85
Gambar 5.8 posisi genggaman usulan operator penjahitan ...................................................85
Gambar 5.9 posisi memegang dan melipat karung operator sebelum perbaikan ....................85
Gambar 5.10 posisi usulan memegang dan melipat karung operator sebelum perbaikan ......86
Gambar 5.11 posisi meraih karung operator loader sebelum perbaikan ...............................86
Gambar 5.12 posisi usulan meraih karung operator loader ...................................................87
Gambar 5.13 posis memegang karung operator loader sebelum perbaiakan .........................87
Gambar 5.14 posisi memegang karung operator loader .......................................................88
Gambar 5.15 posisi menganggkat pupuk ke pallet operator loader sebelum perbaikan .........88
Gambar 5.16 posisi mengangkat pupuk ke pallet operator loader ........................................89
Gambar 5.17 grafik perbandingan nilai ocra .......................................................................109
Gambar 5.18 presentasi penurunan nilai ocra index..............................................................109
15
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