PT ABC merupakan perusahaan cetak dalam skala nasional. Produk yang dihasilkan oleh perusahaan merupakan buku ajar, majalah, surat kabar, dan lain sebagainya. Kegiatan maintenance yang ada PT ABC terbagi menajadi dua, yaitu preventive maintenance setiap senin dan kamis serta kegiatan corrective maintenance yang dilakukan jika mesin mengalami kegagalan fungsi. Kegagalan fungsi pada mesin Komori masih cukup tinggi. Oleh karena itu, diperlukan kegiatan pecegahaan untuk meningkatkan reliabilitas mesin. Metode yang dilakukan adalah Reliability Centered Maintenance, yaitu dengan menganalisis failure yang terjadi dengan menggunakan analisis Failure Mode and Effect Analysis dan Decision Worksheet. Hasil dari analisis ini merupakan preventive task masing-masing komponen. Sedangkan untuk menganalisis risiko yang diakibatkan jika mesin mengalami gagal fungsi, yaitu dengan metode Risk Based Maintenance. Hasil yang diperoleh dari nilai risiko yang ditanggung perusahaan ketika mesin mengalami failure, yaitu sebesar Rp965.904.899,36. Berdasarkan hasil pengolahan data pada subsistem kritis diperoleh kesimpulan bahwa enam komponen dilakukan dengan task scheduled on condition, tiga komponen dengan task scheduled restoration, dan enam komponen dengan task scheduled discard. Sedangkan untuk interval waktu dalam pengerjaan preventive maintenance pada komponen tersebut disesuaikan dengan task yang diperoleh. Setelah mendapatkan interval waktu perawatan, kemudian ditentukan biaya perawatan usulan yang dikeluarkan perusahaan, yaitu sebesar Rp971.567.519,69.

No abstract

The paving molding machine is one of the machines used to produce black paving at PT XYZ. Based on the historical data from the engineering maintenance department, this machine has the highest breakdown frequency which affected the low performance and productivity of the machine. To solve this problem, the effectiveness of the paving molding machine was analyzed using overall resource effectiveness (ORE) methods. ORE aims to analyze machine indicators, consisting of readiness, availability of the facility, changeover efficiency, availability of material, availability of manpower, performance efficiency, and quality rate. The ORE analyzed result shows that values of performance efficiency of paving molding machine were 64.54% and still below the standards of the ORE. To increase the ORE, a design of autonomous maintenance (AM) was proposed. The proposed design means the operator is given the responsibility to maintain the basic condition of the machine to minimize the damage of the paving molding machine at PT XYZ. The result of ORE analysis, especially in the performance efficiency, will be an input for the engineering maintenance department to make an AM basic design that can be executed by each of the machine's operators. In general, this research’s novelty is to combine the application of the ORE method with the AM basic design, whereas the AM is one of the pillars of total productive maintenance (TPM).

ABC is a company engaged in the production of automotive spare parts and accessories, especially motorcycles. The problems faced by the company, there is frequent damage to the CNC Milling A. The company applies preventive maintenance and corrective maintenance activities, but these maintenance activities have not yet run optimally. Therefore, a maintenance system is developed to improve machine reliability. The method used is Reliability Centered Maintenance (RCM), with the aim of determining the optimal maintenance interval and estimation of efficient maintenance costs. RCM is done by analyzing the Failure Modes Effect and Critical Analysis (FMECA). The results of the FMECA analysis are in the form of a Risk Priority Number (RPN) that shows the components of rail bearings, spindle bearings, and hoses as critical components of the system. Through the RCM method, the maintenance policy is generated in the form of 2 scheduled on-condition tasks, 2 scheduled restorations, and 3 scheduled discard tasks with maintenance time intervals in accordance with the task category and can save maintenance costs of IDR 175.602.300.Abstrak. PT. XYZ merupakan perusahaan yang bergerak dibidang produksi spare part dan aksesoris otomotif khususnya sepeda motor. Permasalahan yang dihadapi perusahaan yaitu sering terjadinya kerusakan pada mesin CNC Milling A. Perusahaan menerapkan kegiatan preventive maintenance dan corrective maintenance namun kegiatan maintenance ini belum berjalan dengan optimal. Oleh karena itu, dilakukan pengembangan sistem pemeliharaan untuk meningkatkan keandalan mesin. Metode yang digunakan yaitu Reliability Centered Maintenance (RCM) dengan tujuan menentukan interval waktu pemeliharaan yang optimal dan estimasi biaya pemeliharaan yang efisien. RCM dilakukan dengan menganalisis kegagalan dengan analisis Failure Modes Effect and Criticality Analysis (FMECA). Hasil dari analisis FMECA ini berupa nilai Risk Priority Number (RPN) yang menunjukkan komponen bearing rel, bearing spindle dan selang sebagai komponen kritis pada sistem. Melalui metode RCM, dihasilkan kebijakan maintenance berupa 2 scheduled on-condition task, 2 scheduled restoration dan 3 scheduled discard task dengan interval waktu maintenance sesuai dengan kategori task serta dapat menghemat biaya pemeliharaan sebesar Rp175.602.300.

In a manufacturing company, the machine is one of the most important elements in their production process because machine failure can stop the production process. Therefore, the initial step to minimizing losses caused by machine failure can be done by evaluating the machine condition. Evaluation of machine performance is carried out by measuring the effectiveness of the machine with the Overall Equipment Effectiveness (OEE) method. Based on the calculation result, the OEE value of the machine is 68.63% and this value still under the Japanese Institute of Plant Maintenance standard. Six big losses analysis is performed to determine the biggest loss that affects the effectiveness of the machine. The result of six big losses calculation shows that the most influential factor for the low OEE value of the machine is Reduced Speed Loss (39.12%). Causal analysis with a fishbone diagram is done to find out the causes of the highly reduced speed loss. To calculate the equipment cost loss use the Overall Equipment Cost Loss (OECL) methods. The total of the overall equipment cost loss is IDR 849, 839, 947.53.