Determination of Production Instrumentation Equipment Maintenance Intervals In the Paper Industry

PT. XYZ is a manufacturing industry engaged in paper processing with afval raw materials. The problem faced is machine failure that occurs suddenly without predictability, this is because there is no scheduled maintenance (preventive main-tenance). The object of this research is focused on production instrumentation equipment. This study uses the Failure Mode and Effect Analyzer (FMEA) method to identify the causes of failure and the effects of these failures by determining the critical value of the component, namely the Risk Priority Number (RPN) which is the largest, then the Reliability Centered Maintenance (RCM) II Decision Worsheet method for determine maintenance intervals of production instrumentation equipment. Based on the results of RPN calculations in the FMEA method to determine the critical components of the Instrumentation equipment, namely the Control Valve, it can be seen that the highest total RPN value is found in three components, namely Restrictor with an RPN value of 390, Power Supply with RPN of 297, and also a Pilot Positioner. with an RPN value of 240. And with optimum maintenance intervals, among others, the Restrictor every 40 hours, the Power Supply every 41 hours, and the Pilot Positioner every 47 hours.

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ANALYSIS OF THE IMPACT OF ELIMINATION EIGHT MAJOR LOSSES IN CO-GENERATION POWER PLANT TO INCREASE PROFITS IN THE PULP & PAPER MILLS MANUFACTURING INDUSTRY

Psychology and Education Journal ◽

10.17762/pae.v57i9.3482 ◽

2021 ◽

Vol 57 (9) ◽

pp. 6574-6583

Author(s):

Muhammad Ayip Fathani, Erry Rimawan, Antonius Setyadi, Bambang Setiawan

Keyword(s):

Manufacturing Industry ◽

Business Processes ◽

Raw Materials ◽

Paper Industry ◽

Production Costs ◽

Plant Production ◽

Success Factor ◽

Paper Mills ◽

Pulp Paper ◽

The Impact

In the industrialized world, increasing productivity and profitability is very important for companies as a benchmark of success in business processes. Some literature has defined the success factor of the successful application of the concept of TPM as a tool to improve the productivity performance of the company, therefore improving the productivity performance of the company becomes the main thing in improving long-term sustainable profitability for the company . In the manufacturing industry pulp and paper mills, the contribution of the highest production costs is in raw materials (Pulp and chemical raw materials), followed by energy and packaging. The energy sector occupies the top three in the cost contributor to variable costs, it is triggered because in the pulp paper industry sector, the consumption value for electrical energy and heat is very high. Therefore, success in eliminating eight major losses is a major success factor in improving the profitability of the company. To analyze the effects of elimination of eight major losses, reduction of production costs and increase in profitability can be solved by evaluating the influence of all indicators of eight major losses using PLS-SEM. The data used is operational data co-generation plant production of PT. XYZ in 2019. From the research conducted it is known that the variable Overall Plant Effectiveness (OPE) is significantly influenced by 2 (two) of the 3 (three) constituent indicators, namely Availability and Performance, both indicators affect: Productivity Improvement, Decreased Production Costs and Increased Profitability of the Company. The priority of improvement that must be done by considering the production cost performance data from the review of variable costs of energy is elimination: Loss Shutdown losses (A1), Loss Production adjustment loss (A2), Equipment failure (A3), Process failure ( A4), Normal Production (A5), and abnormal production (A6).

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DETERMINATION OF INVENTORY PERIODIC REVIEW POLICY (R, s, S) USING POWER APPROXIMATION METHOD FOR MINIMIZE TOTAL INVENTORY COST IN PT. OPQ

International Journal of Innovation in Enterprise System ◽

10.25124/ijies.v3i01.33 ◽

2019 ◽

Vol 3 (01) ◽

pp. 47-52

Author(s):

Ratnawia ◽

Rio Aurachman ◽

Saskia Puspa Kenaka

Keyword(s):

Manufacturing Industry ◽

Raw Materials ◽

Service Level ◽

Raw Material ◽

Periodic Review ◽

Inventory Cost ◽

Automotive Manufacturing ◽

Power Approximation ◽

Total Inventory

OPQ is a company engaged in the automotive manufacturing industry. The company produces bolts for the safety area, it is related to the lower body of the four-wheeled vehicle. PT. OPQ was established in 2014 and today has already been the supplier for several major automotive companies in Indonesia. The demand of PT OPQ that must be fulfilled is increasing as the amount of consumer is increasing too. Due to the high demand, so the raw material stockout occurs. This make the company's service level is below the standard. This study involved 48 sku of material raw materials that have normal distributed demand. Inventory policy applied in this research is periodic review (R, s, S) with the aim to minimize total cost of inventory and improve service level of company. The result of this research was found to decrease total inventory cost by 15% with the value of existing inventory cost Rp1.100.879.479,- to Rp 936.061.349,- . In addition, service level at PT. OPQ has increased with the value of existing conditions 85% to 99%. Keywords—Raw Material, Periodic Review, Probabilistic, Service Level, Stock out

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

EKOMABIS: Jurnal Ekonomi Manajemen Bisnis ◽

10.37366/ekomabis.v1i02.29 ◽

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).

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DETERMINATION OF INVENTORY PERIODIC REVIEW POLICY (R, s, S) USING POWER APPROXIMATION METHOD FOR MINIMIZE TOTAL INVENTORY COST IN PT. OPQ

International Journal of Innovation in Enterprise System ◽

10.25124/ijies.v3i01.108 ◽

2019 ◽

Vol 3 (01) ◽

Author(s):

Ratna Wia ◽

Rio Aurachman ◽

Saskia Puspa Kenaka

Keyword(s):

Manufacturing Industry ◽

Raw Materials ◽

Service Level ◽

Raw Material ◽

Periodic Review ◽

Inventory Cost ◽

Automotive Manufacturing ◽

Power Approximation ◽

Total Inventory

PT. OPQ is a company engaged in the automotive manufacturing industry. The company produces bolts for the safety area, it is related to the lower body of the four-wheeled vehicle. PT. OPQ was established in 2014 and today has already been the supplier for several major automotive companies in Indonesia. The demand of PT OPQ that must be fulfilled is increasing as the amount of consumer is increasing too. Due to the high demand, so the raw material stockout occurs. This make the company's service level is below the standard. This study involved 48 sku of material raw materials that have normal distributed demand. Inventory policy applied in this research is periodic review (R, s, S) with the aim to minimize total cost of inventory and improve service level of company. The result of this research was found to decrease total inventory cost by 15% with the value of existing inventory cost Rp1.100.879.479,- to Rp 936.061.349,- . In addition, service level at PT. OPQ has increased with the value of existing conditions 85% to 99%.

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A recommendation of breakdown maintenance on vehicle engine camshaft line using reliability centered maintenance and FMEA method

Operations Excellence Journal of Applied Industrial Engineering ◽

10.22441/oe.2020.v12.i3.008 ◽

2020 ◽

Vol 12 (3) ◽

pp. 355

Author(s):

Y. Advin Fajar Nugroho ◽

Uly Amrina ◽

Bonitasari Nurul Alfa

Keyword(s):

Time Data ◽

Total Productive Maintenance ◽

Effect Analysis ◽

Breakdown Time ◽

Vehicle Engine ◽

Machine Failure ◽

Reliability Centered Maintenance ◽

Current Availability ◽

Availability Ratio ◽

Fmea Method

A vehicle engine manufacturing company that implements Total Productive Maintenance (TPM) found many breakdowns in the camshaft line from January to May 2019. This study aims to reduce the engine camshaft line breakdown by improving preventive maintenance using the Reliability Centered Maintenance (RCM) method and Failure Mode and Effect Analysis (FMEA). The researchers mapped the breakdown time data per engine and found that the longest breakdown time was on the IGR-0040 engine with 22.23 hours. The current availability ratio of the IGR-0040 machine is 72.88%, and the reliability index is 55%. Furthermore, this research identified machine failure using FMEA and found that six machine components experienced the highest failure rate. The researchers proposed some improvement activities related to the maintenance interval rescheduling period that could increase by 61% reliability

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Analisis Penerapan Overall Equipment Effectiveness Pada Mesin Power Press Combination Forming 60T

Jurnal Sistem dan Manajemen Industri ◽

10.30656/jsmi.v1i2.414 ◽

2017 ◽

Vol 1 (2) ◽

pp. 99

Author(s):

Adi Rusdi Widya

Keyword(s):

Preventive Maintenance ◽

Fault Tree Analysis ◽

Production Performance ◽

Analysis Method ◽

Machine Failure ◽

Reliability Centered Maintenance ◽

Emergency Measure ◽

Standard Value ◽

Critical Components ◽

Mean Time

Corrective action on the engine damage is a temporary emergency measure, so further action is required by conducting maintenance activities, prevention of damage (Preventive maintenance), and able to detect abnormal symptoms before the machine breakdown occurs. The sudden impact of machine damage resulted in disruption of planned production performance so that it is necessary to identify and analyze the factors that cause the machine damage. Establish maintenance method using Autonomous Maintenance, Preventive Maintenance and Reliability Centered Maintenance (RCM) concept to prevent machine failure from the beginning, through fault tree analysis (FTA) method, failure mode effect, and analysis (FMEA), mean time between failure (MTBF ) is an analytical activity for implementing RCM systems on machines and critical components, able to identify and detect symptoms of malfunction before the machine is damaged. The results of the research get better application of maintenance system so that identification of important components can be anticipated from the symptoms of damage. Overall, there is an increase in performance seen from the increase of Overall Equipment Effectiveness (OEE) value, still expected to continue to increase according to JIPM 85% standard value. In conclusion FMEA, FTA, MTBF analysis method can be used to build autonomous maintenance, preventive maintenance and reliability centered maintenance so as to facilitate the production and maintenance in determining the proper maintenance of the machine.

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