scholarly journals EVALUASI MANAJEMEN PERAWATAN DENGAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) II PADA MESIN BLOWING I DI PLANT I PT. PISMA PUTRA TEXTILE

2016 ◽  
Vol 11 (2) ◽  
pp. 73
Author(s):  
Diana Puspita Sari ◽  
Mukhammad Faizal Ridho
Keyword(s):  
Production Process ◽  
Interval Analysis ◽  
Maintenance Cost ◽  
Maintenance Policy ◽  
Total Cost ◽  
Reliability Centered Maintenance ◽  
Critical Components ◽  
Reduction Cost

PT. Pisma Putra Textile adalah perusahaan yang bergerak di bidang pemintalan benang yang memiliki berbagai macam mesin produksi yang cukup sering mengalami kerusakan ketika digunakan pada proses produksi. Oleh karena itu, dibutuhkan kebijakan perawatan optimal yang dapat mengurangi frekuensi kerusakan dan menurunkan biaya perawatan mesin.. Metode yang diterapkan pada penelitian ini adalah Reliability Centered Maintenance (RCM) II. Penelitian difokuskan pada mesin Blowing I, karena memiliki downtime tertinggi. Berdasarkan frekuensi kerusakan mesin komponen yang paling sering rusak yaitu flat belt dan apron berpaku. Perawatan yang diperlukan dilakukan pada permukaan belt bergelombang, belt putus, kayu apron patah, dan paku-paku apron patah dengan scheduled discard task dengan interval perawatan dan Total Cost optimal berurutan yaitu 580 jam dengan TC Rp. 14661546,36, 465 jam dengan TC Rp 18350303,77, 490 jam dengan TC Rp 18966057,60, dan 450 jam dengan TC Rp 13419317,27. Sedangkan perawatan untuk kerusakan karet kendor adalah scheduled restoration task dengan interval perawatan 340 jam dan TC Rp 16338431,41. Total penurunan biaya keseluruhan sebesar Rp 21.587.975,45 atau  20,89% dari biaya perawataan perusahaan. Abstract PT. Pisma Putra Textile is a yarn spinning company which have various  production machines which often breakdown on production process. So, the company should have optimum maintenance policy which could reduce breakdown frequency and maintenance cost. The methods which applied in this research is Reliability Centered Maintenance (RCM). Based on data which was given, it shows that Blowing I Machine have the highest downtime so the research focuses on Blowing I Machine. Based on data which was given, it shows that Blowing I Machine have the highest downtime so the research focuses on Blowing I Machine. Based on machine’s breakdown frequency and total downtime, the results shows that the critical components on Blowing I Machine are flat belt and Apron berpaku component. Based on maintenance interval analysis and optimum total cost shows that maintenance for bumpy flat belt surface, flat belt cut-off, spike lattice wood cut-off, spike lattice cut-off with scheduled discard task is 580 hours and Rp 14.661.546,36 ; 465 hours and Rp. 18.350.303,77 ; 490 hours and Rp. 18.966.057,6 ; 450 hours and Rp. 13.419.317,27 respectively. Then, maintenance interval analysis and optimum total cost for flat belt looses with scheduled restoration task is 340 hours and Rp. 16.338.431,41. So, there's a reduction cost Rp. 21.587.975,45 or 20,89% lower than the company's maintenance cost.

scholarly journals Evaluasi Manajemen Perawatan dengan Metode Reliability Centered Maintenance (RCM) II pada Mesin Cane Cutter 1 dan 2 di Stasiun Gilingan PG Meritjan - Kediri

Rekayasa ◽  
2017 ◽  
Vol 10 (2) ◽  
pp. 99
Author(s):  
Cahyo Purnomo Prasetyo
Keyword(s):  
Maintenance Cost ◽  
Repair Cost ◽  
Maintenance Policy ◽  
Work Safety ◽  
Maintenance Costs ◽  
Reliability Centered Maintenance ◽  
Optimal Maintenance ◽  
Critical Components ◽  
Optimal Maintenance Policy ◽  
Production Target

<p>Penelitian ini bertujuan untuk menentukan kebijakan perawatan optimal yang dapat mengurangi biaya perbaikan (repair cost) dan biaya konsekwensi operasional (operational consequence cost). Metode yang diterapkan pada penelitian ini adalah Reliability Centered Maintenance (RCM) II. Penelitian ini difokuskan pada mesin Cane Cutter 1 dan 2 dengan pertimbangan beberapa aspek yaitu : pengaruh kegagalan terhadap pencapaian target produksi, resiko keselamatan kerja dan biaya perawatan yang akan ditimbulkan. Dari hasil penelitian dapat diketahui bahwa komponen kritis pada mesin Cane Cutter 1 dan 2 adalah : Pisau dan Baut Pisau. Perawatan yang dilakukan untuk mengantisipasi dan mengatasi kegagalan yang terjadi pada komponen mesin tersebut adalah proactive task yang meliputi : scheduled restoration task dan scheduled discard task. Rata-rata penurunan biaya perawatan total yang didapatkan dengan mengurangkan ‘biaya total pada interval perawatan awal’ dan ‘biaya total pada interval perawatan optimal’ adalah 14,82 %.</p><p>Kata Kunci: cane cutter, downtime, pabrik gula.</p><p><strong> </strong></p><p><strong>ABSTRACT</strong></p><p><em>This research aims to determine the optimal maintenance policy which could reduce repair cost and operational consequence cost. The methods which applied in this research is Reliability Centered Maintenance (RCM) II. This research focuses on Cane Cutter 1 and 2 machines by considering several aspects, such as and effect of any failure on production target achievement, work safety risk and maintenance cost which might be caused by the critical condition. The result showed that some critical components at the Cane Cutter 1 and 2 machines were : Blade and Blade Bolt. The maintenance which could be done to anticipate and deal with any failure occurring in the machine components was called proactive task comprising : scheduled restoration task and scheduled discard task. The average reduction in total maintenance costs which was obtained by subtracting ‘total costs at initial maintenance interval’ and ‘total costs at optimal maintenance interval’ amounted to 14,82 %.</em></p><p><em>Keywords: cane cutter, downtime, sugar factory</em></p>

scholarly journals Integration of maintenance systems

2018 ◽  
Vol 211 ◽  
pp. 03010
Author(s):  
S H Sarje
Keyword(s):  
Preventive Maintenance ◽  
Hazard Rate ◽  
Reduction Factor ◽  
Maintenance Cost ◽  
Cost Ratio ◽  
Imperfect Maintenance ◽  
Maintenance Policy ◽  
Maintenance System ◽  
Reliability Centered Maintenance ◽  
High Flexibility

Excellence in maintenance is imperative in highly competitive market because it resulted into minimum maintenance cost, high equipment effectiveness, maximum reliability of the system, high quality of the products, low delivery time, high flexibility, safety etc. Any maintenance system such as Total Productive Maintenance (TPM) or Reliability Centered Maintenance (RCM) or Condition Based Maintenance (CBM) alone cannot achieve the excellence in maintenance but its integration may do. In this paper, an integration of TPM, RCM and CBM is proposed with a maintenance policy to take advantage of their respective strengths. A continuously monitored system subject to degradation due to the imperfect maintenance, where a hybrid hazard rate based on the concept of age reduction factor and hazard rate increase factor to predict the evolution of the system reliability in different maintenance cycles has been assumed.A quantitative decision making model for an integrated maintenance system is derived in order to assess the performance of the proposed maintenance policy. Numerical examples of calculation of optimal preventive maintenance age x and preventive maintenance number N* for the given cost ratio of corrective replacement and predictive preventive maintenance are given.

scholarly journals RCM (RELIABILITY CENTERED MAINTENANCE): THE IMPLEMENTATION IN PREVENTIVE MAINTENANCE (CASE STUDY IN AN EXPEDITION COMPANY)

2020 ◽  
Vol 1 (02) ◽  
pp. 197-212
Author(s):  
Fathurohman Fathurohman ◽  
Slamet Triyono
Keyword(s):  
Steering System ◽  
Maintenance Policy ◽  
Power Steering ◽  
Reliability Centered Maintenance ◽  
Coupling System ◽  
Maintenance Time ◽  
Critical Components ◽  
Fmea Method ◽  
And Function ◽  
System Coupling

Expedition truck is a vehicle that serves to transfer goods from one place to another. Previously maintenance policy was periodic, depending on the run distance and Run To Failure, maintain the trucks after the occurrence of component damage then system failure. Analysis in maintenance management based on system and critical components do optimize truck performance by using RCM (Reliability Centered Management) method. There are 5 systems in a truck: electrical system, power steering system, cooling machine system, coupling system, and brake system. Interaction and function of the components from each system are analyzed, evaluated the failure mode (FMEA method), and categorized the level of critical damage and adjusted the maintenance time (LTA method).  The results of the RCM method for 16 component functions from the 5 systems are 5 component functions with Time Directed (TD), 6 Condition Directed (CD), 3 Failure Finding (FF), and 2 component functions by Run To Failure (RTF).

scholarly journals Implementation of Maintenance Scenario for Critical Subsystem In Aircraft Engine: Case Study NTP CT7 Engine

2017 ◽  
Vol 1 (02) ◽  
pp. 52
Author(s):  
Fransiskus Tatas Dwi Atmaji ◽  
Anna Annida Noviyanti ◽  
Widia Juliani
Keyword(s):  
Aircraft Engine ◽  
Maintenance Cost ◽  
Optimal Time ◽  
Time Interval ◽  
Performance Loss ◽  
Maintenance Schedule ◽  
Failure Data ◽  
Reliability Centered Maintenance ◽  
Critical Components ◽  
Critical Subsystem

An aircraft company needs to "secure" their aircraft engine for a good maintenance system to keep the optimum engine's performance during the flight. This paper proposed maintenance analysis and scenario for the CT7, the main engine for aircraft at NTP company. A failure data record from four critical components of the CT7 engine is analyzed using Reliability Centered Maintenance (RCM) and Risk Based Maintenance (RBM) methods to obtain the optimum maintenance interval task for the critical subsystem of the CT7 engine and also seeing the risk of maintenance cost of the engine's failure effect. The RCM analysis result obtained seven scheduled on condition task, six scheduled discard task, and three scheduled restoration task. The interval of the maintenance schedule of each critical component varies according to the function obtained. And based RBM analysis, the risk from system performance loss is got $ 7.014.841, 90. Meanwhile, the total cost of maintenance interval based on a calculation of optimal time interval got $1.885.612, 82.

scholarly journals Evaluasi Kinerja Pemeliharaan Mesin PLTD dengan Menggunakan Pendekatan Reliability Centered Maintenance (RCM)

2017 ◽  
Vol 6 (2) ◽  
Author(s):  
Firman Firman ◽  
Muthia Roza Linda ◽  
Renti Febtri Suci
Keyword(s):  
Effective Treatment ◽  
Mechanical Energy ◽  
Total Cost ◽  
Electric Generator ◽  
Injection Pump ◽  
Major Constraint ◽  
Reliability Centered Maintenance ◽  
Repair Costs ◽  
Critical Components ◽  
Engine Components

Diesel Powered Electric Generator is a Electric Generator where using Diesel Machine as primer mover, which function to produce mechanical energy required to rotate the rotor generator to produce the electricity. The problem faced is found a lot of damage whice is make engine machine does not operate and high repair costs that result the company suffered losses. Reliability Centered Maintenance is a method where used to find “what should you do” to determine effective treatment. The result Showed that the machine has a major constraint on the machine RUSTON 1 is Injection Pump and Cylinder Linier Infection Pump with maintenance intervals about 44.24 hours. The Failure factor of the engine components are the supply of engine’s fuel is not optimal. Total cost for cumulative maintenance of two critical components reach Rp. 831.263.531.  Keywords: Maintenance,  Reliability Centered Maintenance (RCM)

scholarly journals IMPLEMENTATION OF MAINTENANCE SCENARIO FOR CRITICAL SUBSYSTEM IN AIRCRAFT ENGINE Case study: NTP CT7 engine

2018 ◽  
Vol 2 (01) ◽  
pp. 50-59
Author(s):  
Fransiskus Tatas Dwi Atmaji ◽  
Anna Annida Noviyanti ◽  
Widia Juliani
Keyword(s):  
Aircraft Engine ◽  
Maintenance Cost ◽  
Optimal Time ◽  
Time Interval ◽  
Performance Loss ◽  
Maintenance Schedule ◽  
Failure Data ◽  
Reliability Centered Maintenance ◽  
Critical Components ◽  
Critical Subsystem

An aircraft company needs to "secure" their aircraft engine for a good maintenance system to keep the optimum engine's performance during the flight. This paper proposed maintenance analysis and scenario for the CT7, the main engine for aircraft at NTP company. A failure data record from four critical components of the CT7 engine is analyzed using Reliability Centered Maintenance (RCM) and Risk Based Maintenance (RBM) methods to obtain the optimum maintenance interval task for the critical subsystem of the CT7 engine and also seeing the risk of maintenance cost of the engine's failure effect.  The RCM analysis result obtained seven scheduled on condition task, six scheduled discard task, and three scheduled restoration task. The interval of the maintenance schedule of each critical component varies according to the function obtained. And based RBM analysis, the risk from system performance loss is got $ 7.014.841, 90. Meanwhile, the total cost of maintenance interval based on a calculation of optimal time interval got $1.885.612, 82. Keywords— preventive maintenance, reliability-centered maintenance, risk-based maintenance, risk priority number.

scholarly journals The Proposed Maintenance Task for Plastic Injection Machine Using Reliability and Risk Centered Maintenance (RRCM) method in Manufacturing Industry

2019 ◽  
Vol 10 (2) ◽  
Author(s):  
Liza Nafiah Maulidina ◽  
Fransiskus Tatas Dwi Atmaji ◽  
Judi Alhilman
Keyword(s):  
Manufacturing Industry ◽  
Maintenance Cost ◽  
Time Interval ◽  
Maintenance Policy ◽  
Risk Matrix ◽  
Maintenance Time ◽  
Optimal Maintenance ◽  
Critical Components ◽  
The Cost ◽  
Plastic Injection

The objective of this research was to determine the optimal maintenance time interval for the selected critical components and the total cost of maintenance of a plastic injection machine. In determining the critical components, a risk matrix was used, and three components were selected, namely, hydraulic hose, barrel, and motor. Using the Reliability and Risk Centered Maintenance (RRCM) method, the researchers got a proposed maintenance policy and the total maintenance cost. Based on the result, it shows that there are seven proposed maintenance tasks with three scheduled oncondition tasks and four scheduled restoration tasks with an average maintenance interval of two months. The total maintenance cost proposed is IDR91.595.318. The cost is smaller compared to the actual maintenance costs of the company.

scholarly journals Maintenance Preventive Scheduling of Critical Components in Offset Printing Machine (Case Study : PT. XYZ)

Tibuana ◽  
2021 ◽  
Vol 4 (02) ◽  
pp. 110-119
Author(s):  
Marcy L. Patiapon
Keyword(s):  
Production Process ◽  
Critical Component ◽  
Offset Printing ◽  
Maintenance Schedule ◽  
Machine Maintenance ◽  
Reliability Centered Maintenance ◽  
Critical Components ◽  
Printing Machine ◽  
Component Replacement

Maintenance activities are generally considered as supporting activities in the production process. However, this activity is very important because it contributes directly to the smooth running of the production process and productivity. PT. XYZ is a company engaged in mass media or newspapers since September 8, 2015. In the newspaper production process, PT. XYZ experienced delays in the production process due to damage to the component parts of the printing machine, in which the Offset printing machine is the core printing machine that is always used to print newspapers. Based on data on the frequency of damage during 2020 which was obtained from observations and interviews with operators, damage to machine components for 1 year on the offset printing machine counted 73 times that it was damaged. Thus making the machine stop operating from the effective working time of the machine, which is 264 days/year. This is due to the unavailability of a machine maintenance schedule because the company is still implementing a breakdown maintenance system. Thus the researcher aims to calculate the value of the identified critical components and calculate the effective time of machine operation for scheduling replacement of critical components of offset printing machines using the Reliability Centered Maintenance method. Based on the results of data processing using the Reliability Centered Maintenance method, the contactor component is determined as a critical component where the value of the Risk Priority Number is 72 with an average checking time of 11,250 minutes and component replacement time of 7 times/year. For this reason, it can be concluded that the contactor is a critical component with a damage value of 72 and the scheduling time for component replacement is 7 times in 1 year.

The Comparison between Cost and Benefit Business Model of Organic and Chemical Agricultural Vegetable Farming System

2020 ◽  
Vol 11 (1) ◽  
pp. 133-133
Author(s):  
Peerasak Puengpapat
Keyword(s):  
Production Process ◽  
Organic Farming ◽  
Business Model ◽  
Return On Investment ◽  
Agricultural Sector ◽  
Organic Production ◽  
Total Cost ◽  
Cost And Benefit ◽  
Net Profit ◽  
Organic Vegetables

This research is intended to compare and demonstrate the difference between the cost and benefit of organic farming and chemistry. Compare differences in the quality of yields and minerals in the soil both before and after cultivation and modeling of agribusiness. Using Business Model Canvas for the decision of agricultural entrepreneurs who want to modify the farming process.The research found that in the experiment comparing between the costs of Organic farming and Chemical farming to produce three types of vegetables that are cucumber ,red oak salad and radish, with the total cost of growing vegetables in Organic farming, higher than the total cost of growing vegetables in Chemical farming. There is a greater frequency of fertilizing and injecting Organic matter than chemical farming. The net profit from the sale of vegetables in the Organic agricultural sector is higher than the net profit from the sale of vegetables in the Chemical agricultural sector, as the production price of Organic agricultural sector is higher than the production price of Chemical agricultural sector because the production process of organic farming has a higher production process and requires higher production attention to produce quality, and another factor is that Organic vegetables have a higher production cost than vegetables from chemical farming, resulting in less volume of organic production in the market than vegetables from Chemical agricultural sector. Consumers are demanding more healthy Organic vegetables. As a result, the price of vegetables that produced by Organic agricultural sector is higher than the price of vegetables that produced by Chemical agricultural sector, and the Return on Investment in Organic vegetables is higher than the vegetables that produced by Chemical agricultural .The Return on Investment in production of Organic farming is 61.48% and The Return on Investment in production of Chemical farming is 33.87%. It is therefore possible to conclude that growing vegetables in Organic way is safe for vegetable farmers who do not have to be exposed to any harmful Chemicals, as well as the resulting produce that is safe from residues, allowing consumers to be safe from toxin residues and receive good quality vegetables. Type of Paper: Empirical/Experimental Keywords: Agricultural; Organics; Cost ;Business Model ;Comparison.

Availability analysis and maintenance optimization for multiple failure mode systems considering imperfect repair

2021 ◽  
pp. 1748006X2110127
Author(s):  
Qingan Qiu ◽  
Baoliang Liu ◽  
Cong Lin ◽  
Jingjing Wang
Keyword(s):  
Failure Modes ◽  
Maintenance Cost ◽  
Imperfect Maintenance ◽  
Maintenance Policy ◽  
Cost Rate ◽  
Availability Analysis ◽  
Long Run ◽  
Optimal Maintenance ◽  
Maintenance Policies ◽  
Periodic Inspections

This paper studies the availability and optimal maintenance policies for systems subject to competing failure modes under continuous and periodic inspections. The repair time distribution and maintenance cost are both dependent on the failure modes. We investigate the instantaneous availability and the steady state availability of the system maintained through several imperfect repairs before a replacement is allowed. Analytical expressions for system availability under continuous and periodic inspections are derived respectively. The availability models are then utilized to obtain the optimal inspection and imperfect maintenance policy that minimizes the average long-run cost rate. A numerical example for Remote Power Feeding System is presented to demonstrate the application of the developed approach.

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