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

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.

Download Full-text

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

J TI UNDIP JURNAL TEKNIK INDUSTRI ◽

10.14710/jati.11.2.73-80 ◽

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.

Download Full-text

Pendekatan Lean Manufakturing Dalam Pabrik Kelapa Sawit di Aceh Barat

Talenta Conference Series Energy and Engineering (EE) ◽

10.32734/ee.v2i2.434 ◽

2019 ◽

Vol 2 (2) ◽

Author(s):

Fitriadi

Keyword(s):

Production Process ◽

Waiting Time ◽

Palm Oil ◽

Lean Manufacturing ◽

Maintenance Schedule ◽

Oil Processing ◽

Machine Maintenance ◽

Manual Sorting ◽

Excess Production ◽

Operational Excellence

Lean Manufacturing adalah cara berkelanjutan untuk mencapai keunggulan operasional pada proses produksi dan dapat diterapkan segala sector operasional di pabrik. Lean Manufacturing adalah salah satu cara yang dapat digunakan perusahaan kelapa sawit untuk melihat tingkat pemborosan pada proses produksi, sehingga mampu menekan biaya atau bahkan dapat mengurangi kegiatan yang tidak diperlukan dalam proses produksi. Tahapan yang dilakukan untuk mengetahui tingkat pemborosan yang terjadi pada pabrik kelapa sawit adalah melakukan identifikasi pemborosan, melakukan pemetaan pemborosan dan memberikan usulan perbaikan untuk mengurangi pemborosan. Pemborosan atau waste pada proses produksi pengolahan kelapa sawit didapatkan empat stasiun kerja yang mengalami pemborosan yaitu stasiun kerja penyortiran, stasiun kerja loading ramp, stasiun kerja sterilizer dan stasiun kerja thressing. Berdasarkan hasil identifikasi didapat enam jenis pemborosanyaitu kelebihan produksi (Over Production), Waktu tunggu (waiting time), Perpindahan (Transportation), Pergerakan (motion), Persediaan (Inventory), dan produk cacat (defect). Rekomendasi perbaikan yang diberikan untuk mengatasi masalah pemborosan tersebut adalah memberikan pelatihan kepada operator, mengurangi penyortiran manual, menambah jumlah operator, pelatihan perawatan mesin secara mandiri oleh operator (autonomus maintenance), membuat jadwal perawatan mesin secara harian (Berkala, adanya informasi petunjuk kerja pada setiap stasiun dan melakukan perhitungan persediaan optimal. Lean Manufacturing is a sustainable way to achieve operational excellence in the production process and can be applied to all operational sectors in the factory. Lean Manufacturing is one method that can be used by oil palm companies to see the level of waste in the production process, so as to reduce costs or even reduce activities that are not needed in the production process. The step taken to find out the level of waste that occurs in the palm oil mill is to identify waste, carry out waste mapping and provide improvement proposals to reduce waste. Waste or waste in the palm oil processing production process obtained four work stations that experienced waste, namely sorting work stations, loading ramp work stations, sterilizer work stations and pressing work stations. Based on the results of identification obtained six types of waste, namely excess production (Over Production), Waiting time (waiting time), Displacement (Transportation), Movement (motion), Inventory (Inventory), and defective products (defects). Recommendations for improvements given to overcome these waste problems are to provide training to operators, reduce manual sorting, increase the number of operators, train machine maintenance independently by operators (autonomous maintenance), schedule daily maintenance of machines (Periodically, information on work instructions for each station and perform optimal inventory calculations.

Download Full-text

The Preventive Maintenance Schedule: A Case Study at Aman Sales and Services Sdn. Bhd. and Ladang Sabah Palm Oil Mill.

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.660.995 ◽

2014 ◽

Vol 660 ◽

pp. 995-999

Author(s):

Abdullah Mohd Tahir ◽

Jamrin Jasmin ◽

Alfero Sualin ◽

Noor Ajian Mohd-Lair ◽

Abdul Kadir bin Abdul Rahman

Keyword(s):

Palm Oil ◽

Preventive Maintenance ◽

Study Data ◽

Maintenance Schedule ◽

Machine Maintenance ◽

Maintenance System ◽

Breakdown Time ◽

Palm Oil Mill ◽

Maintenance Schedules

Maintenance is crucial to system performance and reliability of a machine for an industry. Machine maintenance system in small and medium industries in Malaysia usually consists of manual file management system, which records all the conducted maintenance works. However, a maintenance system should be more complex to include the scheduling of maintenance activities. This paper presents the findings of studies on the implementation of preventive maintenance schedule conducted at Aman Sales And Services Sdn. Bhd. and Ladang Sabah Palm Oil Mill both located in Sabah, Malaysia. In this study, data form previous maintenance works or activities were collected from both companies. The data were then analyzed. The analysis indicates that reduction in time can be obtained by combining similar or repetitive tasks guided by recommendation from the machines’ manuals. This analysis provides foundation for developing an improved preventive maintenance schedule for each company. The new preventive maintenance schedules are found to be able to reduce the breakdown time ranging from as low as 25% to as high as 50%. This reduction signifies the efficiency of the proposed maintenance schedule.

Download Full-text

Penentuan Interval Waktu Perawatan Komponen Kritis pada Mesin Turbin Di PT Pln (Persero) Sektor Pembangkit Ombilin

Jurnal Optimasi Sistem Industri ◽

10.25077/josi.v14.n2.p238-258.2015 ◽

2016 ◽

Vol 14 (2) ◽

pp. 238

Author(s):

Taufik Taufik ◽

Selly Septyani

Keyword(s):

Power Generation ◽

Production Process ◽

Continuous Process ◽

Electrical Energy ◽

Time Interval ◽

Critical Component ◽

Turbine Engine ◽

Critical Components ◽

Criticality Analysis

Electrical energy requirements in Indonesia annually increase in line with economic growth and an increase in population. So, PT PLN (Persero) have to be able to fulfill the public demands for electrical energy. One of the power generation existed is Steam PowerGeneration. The condition of power generation depended on the maintenance, so, well maintenance made power plant operated at ease condition. Production process in SteamPower Generation of Ombilin used a closed cycle or continuous process. If a machine or an equipment damaged, it will stop the whole function. In the production process, the company involved several main engines are boiler, turbine, condenser, and generator. But the damage often occurs in turbine engine which caused the generation power in Steam PowerGeneration of Ombilin can not operate. Therefore, it needs a maintenance action of machinery/equipment to be able to prevent the damage. The right strategy to keep the engine operating is determining the optimal maintenance interval of equipment for minimizing downtime.The stages of this research begin by determining the critical engine with Criticality Analysis method. Then, the determination of the critical components using Pareto diagram. Then, the determination of the probability density function (pdf) and the reliability of critical components. After that, the determination of maintenance intervals of the critical components by using the criterion of minimizing the downtime that will be used to make maintenance scheduling.Based on the processing data has been done, it was found that the critical engine is a turbine engine with a total value is 44 and the critical components of a turbine engine are membrane turbine, bearing and turning gear with the examination time interval for each critical component are 960.48 hours (40 days), 908.57 hours (37 days) and 1150.28 hours (48days). While the preventive replacement intervals for components of turbine membrane is after operating for 3410 hours, the replacement for bearing components can be carried out during overhaul after operating for 8000 hours and the replacement intervals for components of turning gear is after operating for 4500 hours. The reliability values for each critical component before and after preventive maintenance remains the same, but the value of downtime on each component decreases. The total values of availability for each critical component exceeds 95%.

Download Full-text

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

International Journal of Innovation in Enterprise System ◽

10.25124/ijies.v1i01.85 ◽

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.

Download Full-text

Perancangan Jadwal Perawatan Mesin Menggunakan Pendekatan Reliability Centered Maintenance (RCM) pada PT. XYZ

Talenta Conference Series Energy and Engineering (EE) ◽

10.32734/ee.v1i2.245 ◽

2018 ◽

Vol 1 (2) ◽

pp. 211-216

Author(s):

Nurhayati Sembiring ◽

Gita Ade Elvira

Keyword(s):

Palm Kernel ◽

Working Hours ◽

Screw Press ◽

Double Cone ◽

Maintenance Schedule ◽

Reliability Centered Maintenance ◽

Engine Failure ◽

Critical Components ◽

Engine Maintenance ◽

Engine Components

PT. XYZ adalah suatu perusahaan yang bergerak dalam bidang usaha perkebunan dan pengolahan hasil perkebunan.Produk utamanya adalah Minyak Sawit (CPO) dan Inti Sawit (Kernel). Apabila terjadi kerusakan mesin pada saat jam kerja mesin, maka proses produksi tidak berjalan. Untuk itu diperlukan sistem perawatan yang terjadwal. Tujuan dari penelitian ini adalah mengidentifikasi sumber utama kerusakan mesin, menganalisis kerusakan komponen kritis mesin dengan metode Reliability Centered Maintenance dan membuat jadwal perawatan mesin yang terencana. Komponen kritis pada mesin Screw Press yang dianalisaadalah Gearbox, Hydraulic Double Cone dan Van Belt. Hasil penelitian menunjukan selang waktu penggantian komponen Gearbox adalah 94 hari, komponen Hydraulic Double Cone adalah 105 hari dan komponen Van Belt adalah 116 hari. PT. XYZ is a company engaged in the business of plantation and processing of plantation products. Its main products are crude palm oil (CPO) and palm kernel (kernel). If an engine failure occured during engine working hours, the production process does not work. For this reason, a scheduled maintenance system is needed. The purpose of this study is to identify the main source of engine failure, analyze the failure of critical engine components by using the Reliability Centered Maintenance method and making an engine maintenance schedule. The critical components on Screw Press engine which was analyzed were Gearbox, Hydraulic Double Cone and Van Belt. The results showed the replacement interval for Gearbox component was 94 days, Hydraulic Double Cone component was 105 days, and Van Belt component was 116 days.

Download Full-text

Usulan Perawatan Mesin Stitching Dengan Metode Reliability Centered Maintenance

Jurnal Teknik Industri ◽

10.22219/jtiumm.vol16.no2.83-91 ◽

2017 ◽

Vol 16 (2) ◽

pp. 83

Author(s):

Rizki Arga Kurniawan ◽

Heri Mujayin Kholik

Keyword(s):

Block Diagram ◽

Production Quality ◽

Main Concern ◽

Logic Tree ◽

Effect Analysis ◽

Machine Maintenance ◽

Reliability Centered Maintenance ◽

System Maintenance ◽

Critical Components ◽

And Function

Based on industrial competition nowadays, production quality occurs to be the main concern of severals top companies. Method of machine maintenance is a way to incresing their production quality. Nowadays, several companies still using a corrective maintenance to maintain their machine, which is all of machine maintenance only be performed if the machine damaged. This thesis only focus to high frequency stitching machine. This thesis using Reability centered maintenance method to obtain optimum maintenance interval. This method gathers 7 step of data processing, starting from data selection, determinating restricions of the system, descripting the system and function of block diagram, and then FMEA (Failure Mode Effect Analysis) and LTA (Logic Tree Analysis). The result of this method is a correct maintenance action for critical components that included in condition directed and time directed categories. Qulitative analysis for Reliability Centered Maintenance method includes types indectification of maintenance, cause of damage and the occuring failure. Resul of the research contain several maintenance actions for critical components using condition directed method and critical component replace schedule using time directed method. From the suggested system maintenance simulation with RCM method, downtime can be decrease until 47,83%.

Download Full-text

OPTIMIZING THE ROLE OF INKING UNIT IN OFFSET PRINTING MACHINE

KREATOR ◽

10.46961/kreator.v2i2.286 ◽

2021 ◽

Vol 2 (2) ◽

Author(s):

Juliandri . ◽

Anton Hadiwijaya ◽

Yessy Yerta Situngkir

Keyword(s):

Offset Printing ◽

Printing Process ◽

Maintenance Schedule ◽

Potential Problems ◽

Routine Procedures ◽

Printing Machine ◽

Standard Operations

In-depth observations have been made on the printing process using the Heidelberg Speedmaster CD 102 machine. In this process, the ink unit becomes the biggest concern because of its role in the quality of the printout. Observations are made directly in the field on routine procedures carried out and discuss events in the field to identify problems and determine actions. The results of the study indicate that there are several things that must be improved related to the routine maintenance schedule, the technical setup of the inking unit and identification of potential problems as a reference for improving standard operations in the field.Keywords—Inking unit, offset printing machine, speedmaster machine

Download Full-text

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

International Journal of Innovation in Enterprise System ◽

10.25124/ijies.v2i01.17 ◽

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

Download Full-text

Maintenance System of Universal Goss Printing Machine based on failure data using RCM and RCS method

International Journal of Innovation in Enterprise System ◽

10.25124/ijies.v2i02.26 ◽

2018 ◽

Vol 2 (02) ◽

pp. 57-62

Author(s):

Judi Alhilman ◽

Fransiskus Tatas Dwi Atmaji ◽

Valinouski Aulia

Keyword(s):

Preventive Maintenance ◽

Spare Part ◽

Spare Parts ◽

Critical System ◽

Maintenance Schedule ◽

Maintenance System ◽

Failure Data ◽

Reliability Centered Maintenance ◽

Engine Failure ◽

Printing Machine

Over time a machine will get experience a decrease in reliability, causing the engine to be damaged at the time of operation, thus disrupting the production line. To maintain a machine remains reliable then a good maintenance system is required. In this research, we will use Reliability Centered Maintenance (RCM) and Reliability Centered Spare (RCS) analysis on the critical system of Goss Universal printing machine based on engine failure data. The result of RCM analysis obtained the optimal preventive maintenance schedule and the type of treatment, while based on the RCS analysis obtained spare part needs following the maintenance schedule. With the result of this analysis, is expected where the machine will keep good and will continue to operate without a sudden breakdown under the production schedule's need. Based on RCM analysis for each critical subsystem obtained interval preventive maintenance for transfer roller 127.60 hours, Ink fountain roller 24.45 hours, ink form roller 29.23 hours respectively, and the wash-up device is no scheduled maintenance. For spare parts inventory strategies the result using RCS method are: transfer roller104 units, ink fountain roller requires 32 units, ink form roller 36 units and are holding spare policy required, and a wash-up device no holding spare parts. Keywords— Failure data, Maintenance System, RCM, RCS

Download Full-text