Strategies of Maintenance Model for Exercise Book Manufacturing Machine on Paper Industry by Implementing Monte Carlo Simulation Approach

Abstract

PrefaceToday's advance of technology and development of the industry require companies to move quickly in making innovations and specific policies in order to compete in the industrial world. One of the policies that can be applied in the company is the policy on maintenance. Maintenance is all activities conducted to maintain or restore the condition of the equipment or machinery in accordance with the desired function [1].PT. XYZ is a paper manufacturing company in East Java, which produces Exercise Books. In order to meet high demand for its Exercise Book product, the company operates for 24 hours with three shifts. By implementing 24 hours' operating system, the company applies a corrective system to maintain its machine, namely the replacement of component when the machine is damaged. This maintenance system causes frequent sudden machine stopping during production process. It may trigger further damage to raw materials during machinery processing, causing losses for the company. To minimize this, better interval maintenance planning is required in order to reduce the frequency of breakdowns that occur suddenly. Another goal is to minimize downtime and costs due to maintenance activities. In practice it is extremely difficult to determine the operational or maintenance strategy facilities strategies in order to reduce maintenance costs [2]. The uncertainty in preventive maintenance activities can be solved by using model parameters which are made to achieve the expected target. Monte Carlo simulation can predict future performance [3]. The method used for the analysis of maintenance costs must be able to measure the effect of the operating environment on the reliability of the system and measure of uncertainty [4]. Monte Carlo method is often referred to as statistical simulation method. This method can be used in many areas or places to solve the problem containing uncertainty [5].The above-mentioned preliminary researches can be used as consideration in solving the problem at PT. XYZ Company. In order to plan maintenance interval that contains uncertainty we can perform an analysis by implementing Monte Carlo simulation.

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