Analisis Kerusakan Dan Perawatan Mesin (TEM 404) - Pertemuan 2 Versi 2015

8/17/2019 Analisis Kerusakan Dan Perawatan Mesin (TEM 404) - Pertemuan 2 Versi 2015

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Maintenance policiesMaintenance Policies(1)

Failure-Based

Reactive (ReM):- RTF

- CM

- BD

::(2)

(3)

Condition-Based

Predictive (PdM):

- Oil analysis

( 5)

Total-Based

Global (GM):- Optimization Approach

- TPM

::

ME!"#" Maintenance Mana$ement

Preventive (PM):- Calendar:

%ee&ly

Monthly

::

- Running:" R'('

" )'M'

::

-

- Temperat*re analysis

- Press*re analysis

- %ear analysis

- E++iciency analysis

::

()Ris!-Based

Proactive (PaM):

- RCFA

- FMEA , FMECA

- (AOP- RCM \ RCM2

- RB. ::

Classi"ication o" maintenance #olicies$

%&en!ates' 23 *ae+enber, and Pintelon 2 and Gomaa et al$ 25


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Ob/ecti0e o+ maintenance policiesTop 5 Objectives

To

pre0ent

+ail*res6

(azar7s

To

7isco0er

hi77en

+ail*res6(azar7s

To

7etect

early

Fail*res6(azar7s

To

Minimize

the ris& o+

+ail*res6(azar7s

To

correct

+ail*res6

(azar7s

Reacti0e

Policy 859

Pre0enti0e Policy ;Proacti0e

Policy "5


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Ob/ecti0e o+ PM

• To minimize the n*mber o+ brea&7o>ns on criticale@*ipment

• To re7*ce the loss o+ pro7*ction that occ*rs >hene@*ipment +ail*res ta&e place

• To increase the pro7*cti0e li+e o+ all capital e@*ipment

• To ac@*ire meanin$+*l 7ata relati0e to the history o+ allcapital e@*ipment'

• To permit better plannin$ an7 sche7*lin$ o+ re@*ire7maintenance >or&

• To promote better sa+ety an7 health o+ >or& +orce• To ma?imize the ret*rn on capital in0estment

"4


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Maintenance policiesMaintenance Policies(1)

Failure-Based

Reactive (ReM):- RTF

- CM

- BD

::(2)

(3)Condition-Based

Predictive (PdM):

- Oil analysis

( 5)

Total-Based

Global (GM):

- Optimization Approach

- TPM

::

Preventive (PM):- Calendar:

%ee&ly

Monthly

::

- Running:" R'('

" )'M'

::

-

- Temperat*re analysis- Press*re analysis

- %ear analysis

- E++iciency analysis

::

()Ris!-Based

Proactive (PaM):

- RCFA

- FMEA , FMECA

- (AOP- RCM \ RCM2

- RB. ::

Classification of maintenance policies

!"en#ates$ 2%%&' (ae)enberg and Pintelon 2%%*' and +omaa et al 2%%5,


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%hat .s Reliability-Centere7 Maintenance

One definition:

• Reliability Centere7 Maintenance is a maintenance strate$y that

lo$ically incorporates the optim*m mi? o+ reactive' preventive'

condition based and proactive maintenance practices'

Reliability-Centere7

Reacti0e

Maintenance

Pre0enti0e

Maintenance

Con7ition-Base7

Maintenance

Proacti0e

Maintenance

=mall items

on-critical

nli&ely to +ail

Re7*n7ant

=*b/ect to >ear-o*t

Cons*mable replacement

)no>n +ail*re pattern

Ran7om +ail*re Pattern

ot s*b/ect to >ear

PM in7*ce7 +ail*re

RCFA

FMEA FMECA

RB.


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Other 7e+initions

• Reliability-Centere7 Maintenance is a process

*se7 to 7etermine >hat m*st be 7one toens*re that any physical asset contin*o*s to7o >hat its *sers to 7o in its present operatin$

conte?t' 1ohn Mo*bray RCM3

• Reliability-centere7 Maintenance as a process

to establish the sa+e minim*m le0els o+maintenance' 1ohn Mo*bray RCM ..3


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%hat is =AE A """ sai7 abo*t RCM

• Reliability-Centere7 Maintenance 1RCM3Any RCM process shallens*re that all o+ the +ollo>in$ se0en @*estions are ans>ere7

satis+actorily an7 are ans>ere7 in the se@*ence sho>n as +ollo>s:"' %hat are the +*nctions an7 associate7 7esire7 stan7ar7s o+

per+ormance o+ the asset in its present operatin$ conte?t1+*nctions3

'

#' %hat ca*ses each +*nctional +ail*re 1+ail*re mo7es34' %hat happens >hen each +ail*re occ*rs 1+ail*re e++ects3

5' .n >hat >ay 7oes each +ail*re matter 1+ail*re conse@*ences3

G' %hat sho*l7 be 7one to pre7ict or pre0ent each +ail*re 1proacti0etas&s an7 tas& inter0als3

H' %hat sho*l7 be 7one i+ a s*itable proacti0e tas& cannot be +o*n717e+a*lt actions3


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RCM $oals an7 lo$ic

I Determine the +*nction o+the system6component

Ens*re realization o+ inherent sa+ety an7reliability o+ the e@*ipment

RCM Joals RCM Ko$ic

I e ne > a s a *nc ona

+ail*re

Restore e@*ipment to re@*ire7 le0els >hen

7eterioration occ*rs

I E0al*ate the conse@*enceso+ +ail*re

Obtain the in+ormation necessary +or 7esi$nimpro0ements >here inherent reliability is

ins*++icient

I Assi$n a maintenance tas&to pre0ent the +ail*re

Accomplish these $oals at a minim*m totalli+e cycle cost


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RCM (istory"!G - FAA an7 airline tas& +orce

"!G5 - nite7 Airline 7ecision 7ia$ram

"!G; L 1Maintenance =teerin$ Jro*p3 M=J-"

"!Hs - Military .nterest

"!;s - .n7*stry .nterest

"!!s - A=A Facilities

2 - Accepte7 as a Best Practice by Fe7eralFacilities Co*ncil


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%hy Per+orm RCM• Financial bene+its are 7eri0e7 +rom the +ollo>in$:

– Re7*ce7 maintenance e?penses 7*e to elimination o+ maintenance

tas&s – Application o+ A$e E?ploration techni@*es to e?pan7 time bet>een

tas&s

– Re7*ction in the amo*nt o+ reacti0e maintenance per+orme7 by:

• .7enti+yin$ systems +or con7ition monitorin$ by *sin$ RCM analysis• De0elopment o+ an acceptance criteria an7 commissionin$

• .n7irect bene+its – Re7*ction in 7o>ntime

– MRO 1maintenance repair operation3 re7*ction – Fe>er compliance iss*es


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Fail*re Mo7es An7 E++ects Analysis 1FMEA3

• A +ail*re analysis con7*cte7 in the 7esi$n phaseo+ an e@*ipment or systemN also *se7 as a tool +oranalysis in Reliability Centere7 Maintenance1RCM3'

• T$e M./ contains: – Description o+ Fail*re Mo7es – Ca*se an7 E++ects o+ +ail*re

– Probability o+ Fail*re – Criticality o+ Fail*re – Correcti0e6Pre0enti0e Meas*res


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=electin$ maintenance approach• One o+ the main $oal o+ RCM analysis is to select most

appropriate maintenance techni@*e +or any set o+

e@*ipment or systems' Each maintenance action may beclassi+ie7 into +ollo>in$ cate$ory:

–

– Pre0enti0e maintenance• =che7*le7 7iscar7s• =che7*le7 restoration• Re7*n7ancy• Chec&o*ts

– Con7ition base7 maintenance• .nspections• Monitorin$


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=electin$ maintenance approach

Mac$ine01)stem


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R*n-to-+ail*re applications

• se RT if ne3pected ailure is /cceptable

in Terms of 4mpact on: – =a+ety6=ec*rity

–

– Ki+e Cycle Cost

– Re$*latory

– Probability o+ Fail*re is Ko>


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Con7ition Base7 Maintenance 1CBM3

• CBM is the *se o+ a70ance7 technolo$y to sense machineryoperatin$ characteristics s*ch as:

– 0ibration – temperat*re

– press*re etc'

an7 to compare the meas*re7 0al*es o+ these characteristics >ith$istorical data or other pre-establishe7 criteria to assessmachinery con7ition'

CBM permits con7ition base7 rather than time base7 initiation o+the maintenance e++ort to correct any problems i7enti+ie7'


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Total Pro7*cti0e Maintenance

1TPM3

Tah*n "!H" =iichi a&a/ima seoran$ pelopor 7ari &onsep Total pro7*cti0e

Maintenace 1TPM3 7i epan$'

TPM a7alah proses mana/emen yan$ 7i&emban$&an *nt*& menin$&at&an

'

“ Continuously improve all operational conditions, within a production

system; by stim*latin$ the 7aily a>areness o+ all employees” (by Seiichi

Nakaima, !apan, !"#$)

T*/*an a>al 7ari TPM:


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Total Pro7*cti0e Maintenance

1TPM3 -2

Total Pro7*cti0e Maintenance 1TPM3 memp*nyai #t*/*an 7asar:

' '

2' ero peralatan yan$ $a$al secara ta& terencana

#' ero &ecela&aan'


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TPM memp*nyai ; pilar a&ti0itas:

1. Focused improvement (Kobetsu Kaizen) - Continuously even small steps ofimprovement.

2. Planned Maintenance - It focuses on Increasing Availability of Equipments& reducing Breakdown of Machines.

3. Initial Control - To establish the system to launch the production of new

product & new equipment in a minimum run up time.4. Education & Trainin - Formation of Autonomous workers who have skill &

technique for autonomous maintenance.5. Autonomous Maintenance (Jishu Hozen) - It means "Maintaining one's

equipment by oneself". There are 7 Steps in & Activities of Jishu Hozen.6. Quality Maintenance (Hinshitsu Hozen) - Quality Maintenance is

establishment of machine conditions that will not allow the occurrence ofdefects & control of such conditions is required to sustain Zero Defect.

7. Office TPM - To make an efficient working office that eliminate losses.8. Safety, Hygiene & Environment - The main role of SHE (Safety, Hygiene &

Environment) is to create Safe & healthy work place where accidents do

not occur, uncover & improve hazardous areas & do activities that preserve

environment.


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Dasar *nt*& TPM bera&ti0itas a7alah 5=:

Seiri (Sorting out the required or not required items);

Seition (Systematic Arrangement of the required items);Seiso (Cleaniness);Seiketsu (Standardisation);Shitsuke (Self Discipline).

The Pillars & their details

a) Efficient Equipment Utilisation

b) Efficient Worker Utilisationc) Efficient Material & Energy Utilisation

Analisis Kerusakan Dan Perawatan Mesin (TEM 404) - Pertemuan 2 Versi 2015

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