Planning Activities and Maintenance Time Intervals of Induction Machines using The Reliability Centered Maintenance (RCM) II and Age Replacement Method

Engine performance will decrease when it is operated continuously so that maintenance is needed. Improper maintenance time intervals can reduce engine reliability and still causes machine damage suddenly. Therefore, maintenance time intervals must be determined precisely. This study aims to determine the engine maintenance time intervals using Reliability Theory and Age Replacement Model, then calculate the total maintenance cost. The result shows that the application of new maintenance time interval increases machine reliability.

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Interval Waktu Pemeliharaan Berdasarkan Reliability Centered Maintanance (RCM) Pada Kinerja Saluran Udara Tegangan Menengah (SUTM) Perusahaan Listrik Negara

Jurnal Media Teknik dan Sistem Industri ◽

10.35194/jmtsi.v5i2.1459 ◽

2021 ◽

Vol 5 (2) ◽

pp. 110

Author(s):

Very Fernando ◽

Hernadewita Hernadewita ◽

Humiras Hardi Purba

Keyword(s):

Statistical Data ◽

Predictive Maintenance ◽

Time Intervals ◽

Overhead Lines ◽

Medium Voltage ◽

Maintenance Schedule ◽

Reliability Centered Maintenance ◽

Maintenance Time ◽

Data Statistics ◽

Cable Lines

The State Electricity Company (PLN) serves all Indonesian people from Sabang to Merauke with overhead lines and cable lines. The frequency of blackouts in an area due to disturbances in the channel. PLN seeks to suppress disturbances by carrying out maintenance, namely turning it off or without being extinguished. Medium Voltage Air Lines (SUTM) are more frequent disturbances. The worst damage happened to the conductors, Jumpers, and insulators. Damage will often occur if it is not predictable. In order to find out when damage occurs, a method based on Predictive Maintenance is used, namely maintenance based on historical disturbance data statistics. Predictive Maintenance can be realized by using Reliability Centered Maintenance (RCM). From the results of RCM calculations and statistical data on one PLN unit, there is a new value for predictive maintenance time intervals, for conductors maintenance schedule must be carried out every 2 days, Jumpers every 12 days, and isolators every 16 days before serious damage occurs and widespread blackout Perusahaan Listrik Negara (PLN) melayani seluruh masyarakat Indonesia dari Sabang sampai Merauke dengan saluran udara dan saluran kabel. Frekuensi terjadi pemadaman pada suatu wilayah karena adanya gangguan pada saluran tersebut. PLN berupaya untuk menekan gangguan dengan melakukan pemeliharaan, yaitu dipadamkan atau tanpa dipadamkan. Saluran Udara Tegangan Menengah (SUTM) lebih sering terjadi gangguan. Kerusakan terparah ternyata terjadi pada konduktor, Jumper dan isolator. Kerusakan akan sering terjadi apabila tidak mampu diprediksi. Untuk dapat mengetahui kapan akan terjadi kerusakan digunakan metode berbasis Predictive Maintanance, yaitu pemeliharaan berdasarkan statistik data historis gangguan. Predictive Maintenance dapat terwujud dengan menggunakan Relliability Centered Maintanance (RCM). Dari hasil perhitungan RCM dan data statsik pada salah satu unit PLN, maka terdapat nilai baru intuk interval waktu pemeliharaan secara predictive, untuk konduktor harus dilakukan penjadwalan pemeliharaan setiap 2 hari, Jumper setiap 12 hari, dan Isolator setiap 16 hari sebelum terjadi kerusakan yang parah dan pemadaman meluas.

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PENENTUAN INTERVAL PERAWATAN MESIN AIR SEPARATION PLANT SECARA PREVENTIVE DOWNTIME MAINTENANCE DENGAN MENGGUNAKAN METODE AGE REPLACEMENT PADA PT. XYZ

JUMINTEN ◽

10.33005/juminten.v1i3.114 ◽

2020 ◽

Vol 1 (3) ◽

pp. 153-164

Author(s):

Nidaru Ainul Fikri ◽

Endang Pudji Widjajati

Keyword(s):

Air Separation ◽

Time Interval ◽

Compressor Unit ◽

Replacement Method ◽

A Value ◽

Maintenance Time ◽

Purification Unit ◽

Increase Productivity ◽

Age Replacement ◽

The Cost

One way to increase productivity is by reducing downtime on production machine in general, downtime is divided by planned downtime and unplanned downtime. Downtime can be minimized by conducting preventive maintenance. PT. XYZ is a company engaged liquid oksigen, nitrogen and argon manufacturing. In their maintenance system PT. XYZ is still using corrective maintenance method where repair will be conducted if any damage has been occured. There fore this research is conducted to determine maintenance time interval using age replacement method. This research subject is air sparation plant consists of filter unit, recycle nitrogen compressor unit, and argon purification unit. Based on the analysis of the results obtained, it is known that with the age replacement method the optimal component replacement time interval for the Argon Purification Unit component is 32,400 minutes, and the Recycle Nitrogen Compressor Unit is 31,500 minutes. with total annual maintenance costs of Rp. 449,921,405. Compared to the cost of maintenance in companies that have a value of Rp 3,115,210,778, the treatment system using the age replacement method is more efficient at 69,23%.

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Peningkatan Ketersediaan Waktu Operasi Pada Mesin Boiler Berdasarkan Down Time Dengan Pendekatan Metode Reliability Centered Maintenance (RCM) (Studi Kasus PT. Dian Swastika Sentosa, Tbk

Jurnal Sinergi Jurusan Teknik Mesin ◽

10.31963/sinergi.v18i2.2630 ◽

2020 ◽

Vol 18 (2) ◽

pp. 189

Author(s):

Ahmad Zubair Sultan ◽

Muhammad Arsyad Suyuti ◽

Tanhar Bin Naim ◽

Arya A. Amiruddin

Keyword(s):

System Reliability ◽

Production Efficiency ◽

Bottom Ash ◽

Reliability Function ◽

Distribution Data ◽

Boiler Unit ◽

Time Data ◽

Time Intervals ◽

Reliability Centered Maintenance ◽

Maintenance Time

This study aims to (1) determine the subsystem or component that causes the main failure in boiler unit 2 and the effect on production efficiency. (2) Determine the maintenance interval at boiler unit 2 with the Reliability Centered Maintenance method. This research was conducted by processing downtime data from each sub-system or component, which was converted into time data between failures. Thus, testing of the distribution data is to determine the appropriate distribution. Based on the parameters obtained, it is used to determine the reliability function of each subsystem or component. Thus, the reliability value of each component over a certain period of time can be calculated. From the results of the research, the most damage has reliability including ballmill a (29.01%), ballmill b (37,250%), bottom ash a (41,604%), coal feeder a (35,282%), boiler (38,275%), hydraulic (20,236%), soot blower l3 (16,019%), coal feeder b (35,915%). So that reliability is focused on these components or subsystems. Then the maintenance time intervals are arranged as a group maintenance strategy to achieve the targeted system reliability.

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Filling machine preventive maintenance using age replacement method in PT Lucas Djaja

MATEC Web of Conferences ◽

10.1051/matecconf/201815401056 ◽

2018 ◽

Vol 154 ◽

pp. 01056

Author(s):

Fifi Herni Mustofa ◽

Ria Ferdian Utomo ◽

Kusmaningrum Soemadi

Keyword(s):

Maintenance Cost ◽

Time To Failure ◽

High Failure Rate ◽

Corrective Maintenance ◽

Replacement Method ◽

Critical Components ◽

Age Replacement ◽

Engine Maintenance ◽

A Company ◽

Mean Time

PT Lucas Djaja is a company engaged in the pharmaceutical industry which produce sterile drugs and non-sterile. Filling machine has a high failure rate and expensive corrective maintenance cost. PT Lucas Djaja has a policy to perform engine maintenance by way of corrective maintenance. The study focused on the critical components, namely bearing R2, bearing 625 and bearing 626. When the replacement of the failure done by the company is currently using the formula mean time to failure with the result of bearing R2 at point 165 days, bearing 625 at a point 205 days, and bearing 626 at a point 182 days. Solutions generated by using age replacement method with minimization of total maintenance cost given on the bearing R2 at a point 60 days, bearing 625 at the point of 80 days and bearing 626 at a point 40 days.

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Penentuan Interval Waktu Penggantian Komponen Kritis Pada Mesin Volpack Menggunakan Metode Age Replacement

Jurnal Teknik Industri ◽

10.22219/jtiumm.vol16.no2.92-100 ◽

2017 ◽

Vol 16 (2) ◽

pp. 92

Author(s):

Yanuar Yuda Prawiro

Keyword(s):

Cost Savings ◽

Solenoid Valve ◽

Time Interval ◽

Preventive Replacement ◽

Replacement Method ◽

Schedule Interval ◽

Age Replacement ◽

Engine Components ◽

A Company ◽

Replacement Time

CV. Cool Clean is a company engaged in packing tissue. During this time the company only perform corrective action that causes disruption of the production process due to frequent damage of a sudden the engine components volpack. In this study used a model of preventive replacement that can reduce downtime and costs. The method used to obtain the schedule interval a critical component is age replacement method. Seal heater obtained replacement time interval of 30 days with a 22% reduction in downtime. Replacement interval for knife foil is 26 days with a 27% reduction in downtime. Replacement interval for solenoid valve is30 days with a 29% reduction in downtime. Replacement interval forOring seal is 18 days with a 29% reduction in downtime. Replacement interval for needle bearing is 62 days with a 25% reduction in downtime. Results of this study also showed that by applying age replacement can save costs for seal heater Rp. 974.000 or 23%. Knife foil cost savings of Rp. 1.251.409 or 22%. Solenoid valve cost savings of Rp.546.539 or 24%. Oring seal cost savings of Rp. 350.096 or 26%. And needle bearing cost savings of Rp. 196.712 or 26%.

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Establishing simulation model for optimizing efficiency of CNC machine using reliability-centered maintenance approach

International Journal of Modeling Simulation and Scientific Computing ◽

10.1142/s179396231950034x ◽

2019 ◽

Vol 10 (06) ◽

pp. 1950034 ◽

Cited By ~ 2

Author(s):

Zahid Hussain ◽

Hamid Jan

Keyword(s):

Preventive Maintenance ◽

Simulation Software ◽

Time Interval ◽

Total System ◽

Cnc Machine ◽

Effect Analysis ◽

System Cost ◽

Reliability Centered Maintenance ◽

Maintenance Time ◽

Critical Components

The objective of this work was to enhance the product’s quality by concentrating on the machine’s optimized efficiency. In order to increase the machine’s reliability, the basis of reliability-centered maintenance approach was utilized. The purpose was to establish a planned preventive maintenance strategy to identify the machine’s critical components having a noteworthy effect on the product’s quality. The critical components were prioritized using failure mode and effect analysis (FMEA). The goal of the study was to decrease the ppm time interval for a CNC machine by simulating the projected preventive maintenance time interval. For this purpose, the simulation software ProModel 7.5 was implemented for the current preventive maintenance procedure to choose the best ppm time interval which contributed better norms. Five dissimilar optimization approaches were applied, however, the first approach yielded the prominent total system cost and the shorter ppm interval. The results of the study revealed that there was an increase of USD 1878 as a result of an increase in total system cost from USD 78,365 to USD 80,243. Preventive maintenance costs were reduced from USD 4196 to USD 2248 (46%). The costs associated with good parts increased from USD 8259 to USD 8294 (0.4%) and the costs associated with defective parts reduced from USD 171 to USD 3 (98.25%), respectively.

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PERENCANAAN PENJADWALAN DAN PERSEDIAAN SPAREPART DENGAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) DI PT.X

JURNAL TEKNIK INDUSTRI ◽

10.25105/jti.v6i1.1528 ◽

2017 ◽

Vol 6 (1) ◽

Author(s):

Evi Siswanti

Keyword(s):

Opportunity Cost ◽

Production Capacity ◽

Minimum Cost ◽

Maintenance Policy ◽

Reliability Centered Maintenance ◽

Maintenance Activities ◽

Age Replacement ◽

The Cost ◽

Lost Opportunity

PT.X is a supplier company that manufactures plastic bottles. Currently PT.X has a production capacity of 4.3 million bottles per day. The production capacity can be met if the production machine running well and in a reliable state. PT.X not currently have a machine maintenance activities are laid out well. This often caused many damage occurs unscheduled engine which causes the cost of lost opportunity (opportunity cost) for the manufacture of products and the high costs of component inventory. The method used in solving the problem in this study is the use of Reliability Centered Maintenance analysis in determining the policy of treatment and then seek maintenance intervals based on the minimum cost. The results obtained are contained 8 components that have critical categories with each scheduled maintenance policy is age replacement, with this calculation obtained a saving of approximately 44% on inventory costs and increased reliability component approximately 42% -64%.

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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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Optimal Maintenance Schedules of Computer Software

Probability in the Engineering and Informational Sciences ◽

10.1017/s026996480000156x ◽

1990 ◽

Vol 4 (2) ◽

pp. 243-255 ◽

Cited By ~ 3

Author(s):

Nam-Sook Wee

Keyword(s):

Computer Software ◽

Numerical Algorithms ◽

Maintenance Phase ◽

Damage Cost ◽

Time Intervals ◽

Total Cost ◽

Maintenance Time ◽

Optimal Maintenance ◽

Operational Phase ◽

Maintenance Schedules

We present a decision procedure to determine the optimal maintenance intervals of a computer software throughout its operational phase. Our model accounts for the average cost per each maintenance activity and the damage cost per failure with the future cost discounted. Our decision policy is optimal in the sense that it minimizes the expected total cost. Our model assumes that the total number of errors in the software has a Poisson distribution with known mean λ and each error causes failures independently of other errors at a known constant failure rate. We study the structures of the optimal policy in terms of λ and present efficient numerical algorithms to compute the optimal maintenance time intervals, the optimal total number of maintenances, and the minimal total expected cost throughout the maintenance phase.

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