Perawatan Mesin 009

8/7/2019 Perawatan Mesin 009

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PERAWATAN MESIN MS-4102(MAINTENANCE)



BAB I. PENDAHULUAN



PRODUCT LIFE CYCLE• Feasibility Study: apakah suatu mesin/pabrik layak

dibuat ditinjau dari segi ekonomi, lingkungan, teknologi.• Design: gambar desain dan spesifikasi teknik.

• Build: tender, gambar konstruksi, konstruksi, as builtdrawing

• Commissioning: pengujian terhadap performance yangdijanjikan, base line data.

• Operation (untuk menghasilkan produk) & Maintenance(supaya mesin tetap dapat dioperasikan dengan baik).

• Decommissioning: untuk menentukan apakah mesinsudah mencapai akhir umurnya.

• Discard: mesin dibuang dan materialnya didaur ulang.



WHAT IS MAINTENANCE?Contoh:

Kita punya sebuah motor.Apa yang kita lakukansupaya motor tetap dapatberfungsi dengan baik?

Apa tujuan kita memilikisepeda motor? Umumnyatujuan non komersial.

Untung rugi bukanpertimbangan.



WHAT IS MAINTENANCE?• Yang kita lakukan (elemen aktifitas perawatan)

– Membersihkan (lap, cuci)

– Memeriksa (dapat dilakukan sambil membersihkan)– Mengencangkan (mur/baut, jari2 yang kendor, rantai, memompaban, menyetel arah kaca spion, menyetel rem)

– Melumasi (rantai, kabel rem, pedal rem)– Menyediakan suku cadang (bohlam, busi)

– Perbaikan ringan (dilakukan sendiri)– Perbaikan berat (dilakukan oleh bengkel)

• Tujuan– Supaya performancenya tetap baik (performance mesin,

tampilan)– Aman dikendarai– Tidak mencemari lingkungan



WHAT IS MAINTENANCE?



WHAT IS MAINTENANCE?• Untuk suatu pabrik apa yang dilakukan dan tujuannya

serupa dgn untuk motor.

• Jumlah orang yang terlibat lebih banyak• Jumlah dana lebih banyak• Aspek komersial memerlukan pengorganisasian semua

kegiatan:– Strategi perawatan– Penugasan & koordinasi– Inventarisasi aset dan SDM– Penyediaan suku cadang– Pembelian barang dan jasa

– Sistem informasi– Perencanaan perawatan/perbaikan– Penjadwalan perawatan/perbaikan




Pabrik dengan jumlah peralatan dan jenis sangat banyak.• Peralatan putar (rotating equipments)

– Pompa, kompresor, turbin, diesel• Peralatan statik (tidak berputar)

– Pressure vessels, reaction column, knocking drum, heatexchanger, tangki, piping

• Elektrik– Motor listrik, generator, transformer, distribution panels• Instrumen dan sistem kendali

– Pressure gauge, termometer, level meter, flow meter– PLC, DCS

– Hidrolik, pneumatik• Bangunan, prasarana (jalan, gedung, platform, air, bengkel, dlsb)



WHAT IS MAINTENANCE?• Asal kata : to maintain• Arti: (1) memelihara

• Arti: (2) merawat• Arti: (3) menjaga• Apa yang di maintain?

– mesin/peralatan: supaya tidak rusak– performance (kualitas, kuantitas, efisiensi): supaya

memenuhi kriteria– aspek keselamatan: supaya tidak membahayakan

personil– aspek lingkungan: supaya tidak mencemarilingkungan




Performanc

e

Waktu

Dengan

PM

Performance Min

Tanpa

PM




Performance

Waktu

CM CM

PM

Maintenance record

Performance

min



WHAT IS MAINTENANCE?• Teknik (bayangkan anda hanya menghadapi 1 motor)

– Bagaimana melumasi– Bagaimana cara menyetel

– Bagaimana cara membongkar & memasang– Bagaimana cara mendeteksi kerusakan

• Manajemen (bayangkan anda mempunyai 100 motor)– Bagaimana menyediakan “personil”, menentukan tugas dan

wewenangnya– Mendidik, melatih dan menyemangati personil– Merekam data dan informasi– Bagaimana menyediakan dan membeli suku cadang– Bagaimana membuat planning

– Bagaimana menjadwal– Bagaimana menyediakan dana– Bagaimana mengorganisasikan (visi, misi)



WHAT IS MAINTENANCE?• Teknik

– Fokus ke mesin, lebih jelas (bukan berarti mudah)

– Ada manual teknik dari pembuat mesin– Ada catatan sejarah perawatan mesin

– Ada code dan standard (SNI, API, ASME, JIS, DIN dlsb)

– Ada peraturan keselamatan kerja, peraturan lingkungan hidup,OSHA (Occupational Safety and Hazard Association)

• Manajemen– Fokus ke manusia

– Ada ilmunya tapi tidak “exact” seperti yang teknik

– Melibatkan unsur “seni”

– Dipengaruhi budaya setempat (etos kerja, disiplin, rasa memiliki)

– Tergantung xxxx



WHAT IS MAINTENANCE?• Unplanned maintenance: kegiatan perawatan tidak terjadwal

karena keadaan darurat.• Planned maintenance: kegiatan perawatan terjadwal (biasanya

jangka panjang/tahunan). Seringkali mesin produksi tidak dapatdihentikan begitu saja untuk maintenance.

• Breakdown maintenance (RTF = Run To Failure): strategiperawatan dimana mesin dibiarkan saja beroperasi sampaikerusakan terjadi.

• Preventive maintenance: strategi perawatan (cleaning, inspection,small repair, lubrication) untuk mencegah konsekuensi kegagalanpada tingkat komponen maupun tingkat pabrik.

• Corrective maintenance: adalah strategi untuk memperbaikikomponen yang mengalami kegagalan.

• Running maintenance: kegiatan maintenance yang dapatdikerjakan ketika mesin sedang beroperasi• Shutdown maintenance: kegiatan maintenance yang hanya dapat

dikerjakan ketika mesin sedang tidak beroperasi



WHAT IS MAINTENANCE?• Emergency maintenance: kegiatan perawatan/

perbaikan untuk mengatasi kerusakan yang tidakterduga.

• Availability: ketersediaan/kesiapan mesin utkdioperasikan

• MTBF (mean time between failure): jangka waktuantara dua kerusakan berturut-turut.

• MTTR (mean time to repair): jangka waktu untukmenyelesaikan perbaikan.

• Down time: periode waktu dimana mesin tidak dapatdioperasikan

• Facility register (master equipment list): basis dataperalatan, termasuk komponen dan perlengkapannya.




Maintenance

Planned maintenance Unplannedmaintenance

Preventive

maintenance

Corrective

maintenance Emergency

maintenance

Overhaul

Minor Major

Shutdownmaintenance

•Cleaning

•Inspection

•Small repair

Running

maintenance



WHY DO MACHINES FAIL?

• Wajar– Aus (wear): scuffing, galling, fretting, abrasion

– Lelah (fatigue)– Karat (corrosion)– Erosi (erosion)– Penuaan (aging)

• Prematur– Pelumasan tidak bagus (kualitas, kuantitas pelumas,

periode penggantian pelumas tidak benar)– Kotor/kontaminasi

– Overheated– Misalignment (pada kopling, bearing, belt, rantai)



WHY DO MACHINES FAIL?OverheatedBrinelling karena overloaded



WHY DO MACHINES FAIL?

Fatigue damage



FAILURE PATTERN

• Dahulu orang percaya bahwa semua kegagalankomponen mengikuti “bathtub curve”

• Ternyata bathtub curve tsb hanya mencakup 4% dari

populasi komponen (mis: bearings, connector, switches,IC, PCB, etc)

• Age related failure hanya 11%

Failure Rate

Time

Useful life period

(wealth cycle)

Start up

cycleBreak down

cycle

Critical wear point



FAILURE PATTERNArti dari bathtub curve

• Start up cycle: kerusakan terjadi karena ketidak

sempurnaan material, pengerjaan, pemasangan,pelatihan operator. Pada saat awal komponen mesinakan saling menyesuaikan karena berbagai ketidaksempurnaan pembuatan (permukaan masih kasar yangsaling menghaluskan)

• Useful life: mesin berproduksi dengan baik karenakomponen2nya sudah saling menyesuaikan

• Break down cycle: komponen mengalami fatigue,

keausan berlebih, erosi, abrasi dlsb.Bath tube curve cocok untuk komponen mekanik.



FAILURE PATTERN

7%

14%

68%

2%

5%

4%

Age related failure (1, 2, 3)

Artinya: komponen akanrusak ketika sudah tua

Age unrelated failure (4, 5, 6)

Artinya: komponen bisagagal secara random, pada

saat masih muda maupunsesudah tua



FAILURE PATTERN POPULATION

PERCENTAGE

1

2

3

4

5

6



FAILURE PATTERN

1940 1950 1960 1970 1980 1990 2000



Kategori Mesin/Peralatan Produksi• Ditinjau dari tingkat kerumitan, harga,

peranan dan resiko dalam suatu matarantai produksi, mesin digolongkan atas.

– Critical

– Essential (Potentially critical)– General Purpose (Non critical)

• Kategori ini untuk menentukan strategiperawatan yang cocok.



Mesin “Critical”

• Kalau rusak dapat membahayakan

• Kalau rusak proses produksi terganggu

• Investasi mahal

• Biaya perbaikannya mahal (misal: highspeed turbine)

• Waktu untuk perbaikan lama



Mesin “General Purpose”

• Kalau rusak tidak membahayakan

• Kalau rusak tidak mengganggu prosesproduksi

• Investasi tidak mahal• Biaya perbaikan tidak mahal

• Mempunyai unit cadangan

• Tidak mengakibatkan kerusakan sekunder



Mesin Essential (Potentially Critical)

• Di antara mesin critical dan general

purpose.



BAB IIPERKEMBANGAN

STRATEGI PERAWATAN



PERKEMBANGAN

STRATEGI PERAWATAN

• Sebelum PD II rancangan mesin sederhana,

kokoh, berat, “robust”• Perawatan sederhana

• Munculnya sistem produksi massal berarti

kerusakan mesin produksi dapat menimbulkankerugian besar

• Bersamaan dgn itu, rancangan mesinbertambah rumit, ringan, ramping

• Perlu strategi baru dalam perawatan



PERKEMBANGAN

STRATEGI PERAWATAN

Generasi ketiga

-Availability danreliability lebihbaik

-Keselamatan lebih baik

-Kualitasproduk lebihbaik-Tidakmencemari lingkungan

-Umurperalatanlebih panjang

-Efektifitas biaya lebihbaik

Generasi kedua

-Availability lebih baik-Umur peralatanlebih

panjang

-Efektifitas biaya lebihbaikGenerasi pertama

-Perbaiki kalaurusak

Tuntutanyang

semakinmeningkat th

dmaintenance

1940 1950 1960 1970 1980 1990 2000



PERKEMBANGAN

STRATEGI PERAWATAN

Generasi ketiga

-Pemantauankondisi mesin

-Design for reliability andmaintainability

-Hazard studies

-Komputer kecil, cepat

-FMEA-Expert systems

-Multi tasking and teamworks

Generasi kedua

-Overhaul terjadwal-Sistemutk perencanaandan

pengendaliankerja

-Komputer besar danlambatGenerasi pertama

-Perbaiki kalaurusak

1940 1950 1960 1970 1980 1990 2000



PERKEMBANGAN

FILOSOFI PERAWATAN• Break down (run to failure) maintenance : mesin

dioperasikan tanpa perawatan sampai kerusakan terjadi.

Kerusakan primer hampir selalu menimbulkan kerusakansekunder.• Preventive maintenance (PM) atau time base

maintenance: mesin di”maintain ” secara terjadwal

setelah beroperasi dalam jangka waktu tertentu.• Predictive (on condition based) maintenance (PdM):kondisi mesin dipantau secara menerus. Bila terdeteksiadanya ketidak normalan baru diambil tindakan.

• Proactive (prevention) maintenance: kerusakan yangterjadi dicari penyebabnya untuk mencegah kerusakanyang sama berulang.



PERKEMBANGAN

FILOSOFI PERAWATAN

2 year leaseAutomobile tiresOil changeHead lightComponent you

would maintain

Could be

expensive

Costly if

implemented

incorrectly

Unnecessary

replacement of

parts. Poor utilization of labor.

High spare

stock level.

Emergencyoutages

Disadvantages

(when

implementedcorrectly)

Less

maintenancerequired

Can spot potential

failure

Can be planned

for or scheduled

CheapAdvantages

(whenimplemented

correctly)

Redesign toeliminate root

cause of failure

Maintain basedupon known

condition/standard

Conductmaintenance at

regular intervals

Fix it when itbreaks, Run to

Failure

Definition

Proactive

Maintenance

Predictive

Maintenance

Preventive

Maintenance

Reactive,

Run To Failure

Strategy



RunRun--toto--Failure MaintenanceFailure Maintenance

•• RunRun--toto--failure maintenance is sometimesfailure maintenance is sometimes

called "crisis maintenance" for goodcalled "crisis maintenance" for goodreason. This has been the dominant formreason. This has been the dominant formof maintenance for a long time, and itsof maintenance for a long time, and its

costs are relatively high because ofcosts are relatively high because ofunplanned downtime, damagedunplanned downtime, damagedmachinery, and overtime expenditure.machinery, and overtime expenditure.



•• REACTIVEREACTIVE::– – Trouble / Breakdown / RTF / M&RTrouble / Breakdown / RTF / M&R

•• “ “ Fix it when it breaks Fix it when it breaks ” ” – – “ “ Run to failure Run to failure ” ”

•• PREVENTIVEPREVENTIVE (PM):(PM): Functional Checks of EquipmentFunctional Checks of Equipment

– – For Rotating Equipment:For Rotating Equipment:•• LubricationLubrication

•• BeltsBelts

•• FiltersFilters

•• HousekeepingHousekeeping

•• Visual ObservationsVisual Observations– – Work Orders generated Facility Asset ManagementWork Orders generated Facility Asset Management

Information SystemInformation System



Periodic Preventive MaintenancePeriodic Preventive Maintenance•• Periodic preventive maintenance, which is sometimes calledPeriodic preventive maintenance, which is sometimes called

"historical" maintenance. This is where the histories of each"historical" maintenance. This is where the histories of eachmachine type are analyzed and periodic overhauls are scheduled tmachine type are analyzed and periodic overhauls are scheduled too

occur before the statistically expected problems occur. It has loccur before the statistically expected problems occur. It has longongbeen known that most groups of similar machines will exhibit faibeen known that most groups of similar machines will exhibit failurelurerates that are somewhat predictable if averaged over a long timerates that are somewhat predictable if averaged over a long time..This gives rise to the soThis gives rise to the so--called "Bathtub Curve" which relates failurecalled "Bathtub Curve" which relates failurerate to operating time, as follows:rate to operating time, as follows:



PREVENTIVE MAINTENANCE

(TIME BASED)• Preventive maintenance adalah suatu tindakan untuk

menjaga agar peralatan tetap dapat beroperasi dengan

cara inspeksi, deteksi dan pencegahan kerusakan.• Semua kegiatan perawatan dijadwal berdasar waktu

(mingguan, bulanan, triwulanan, 1000 jam, 3000 jamdlsb)

• Pelaksanaan mudah, tinggal mengikuti jadwal:pembersihan, pengecatan, pelumasan, pemeriksaan,perbaikan.(Rencana dan jadwal tahunan harusdisiapkan).

• Penganggaran mudah: anggaran umumnya dibuattahunan.




(TIME BASED)Peralatan apa yang cocok untuk di PM?

• Peralatan yang menyebabkan :– “major shut down”,

– penurunan kualitas produk,

– kerusakan terhadap komponen terkait,

– bahaya kepada karyawan

• Penerangan, lantai, plafon yang dapat mengganggukualitas produksi atau menimbulkan kondisi kerja yangburuk.




(TIME BASED)Peralatan apa yang tidak perlu di PM? (cukup dg RTF)

• Peralatan yang mempunyai cadangan• Peralatan yang harganya lebih rendah dari biaya PM

• Peralatan yang umur harapannya cukup panjang tanpaPM




(TIME BASED)

Co

st

% maintenance delay

Production cost due to delay

Production cost as affected

by maintenance cost

PM cost#1

#3

#2




(TIME BASED)• Rumus empirik untuk menentukan faktor PM (makin

tinggi nilainya PM makin perlu)

PM = D(A+B+C)/(EF)

PM = inspection factor

D = number of break down/year

A = cost of break down repairsB = cost of lost production

C = cost of repairing other equipment involved in thebreakdown

E = cost of PM activity (average)

F = number of PM cycle per year





(TIME BASED)

Do PM (Preventive Maintenance) if number

of break down x Average cost per breakdown x 70% > cost of PM system





(TIME BASED)Optimum Frequency/Interval for PM ditentukan berdasar:• Failure history

• CM history• Manufacturer recommendations• Industry history• Regulatory requirements• Design and operation considerations

• Other tasks scheduled on the same component• Planned outages• Ability to gain access to the component• Operator capability

• PdM monitoring activity• Environment



PM Tasks

Ask operator how machine is operatingInterview operatorHistory analysis of a type of machineAnalysis

Remove and replace pumpScheduled replacement

Add oilLubricate

Read temperature, pressure, vibrationTake reading

Adjust tightening boltAdjusting

Warming up machine/prepare for operationOperating

Tighten anchor boltsTighteningRemove debris from machinesCleaning

Look for leak in hydraulic systemInspection

ExampleType of Task





(TIME BASED)Inspection

• Memastikan performansi peralatan sesuai perancangan

• Mengevaluasi semua komponen terhadap masalah yangpotensial menimbulkan kerusakan

• Mengidentifikasi komponen yang dapat menyebabkan

kerusakan dan mengestimasi waktu sampai kerusakanterjadi. Contoh: dinding pressure vessel mengalamipenipisan selama dioperasikan.





(TIME BASED)Inspeksi dilakukan

• Karena tuntutan peraturan: Pressure vessel harusdiinspeksi secara berkala sesuai dengan peraturanpemerintah tentang keselamatan kerja.

• Karena mesin tidak dilengkapi dengan cadangan dan

beresiko terhadap keberlangsungan proses produksi.• Pada peralatan yang sedang rusak

CORRECTIVE MAINTENANCE (PERBAIKAN) SEBAGAI



CORRECTIVE MAINTENANCE (PERBAIKAN) SEBAGAI

RESPONS TERHADAP INSPEKSI DALAM PM

Biaya perbaikan

Equ

ipment availa

bility



PREDICTIVE MAINTENANCE (PdM)

Preventive Maintenance

Time BasedMaintenance

PredictiveMaintenance,

Condition BasedMaintenance

P di ti M i tPredictive Maintenance



Predictive MaintenancePredictive Maintenance

•• Predictive maintenance allows management to controlPredictive maintenance allows management to controlthe machinery and maintenance programs rather thanthe machinery and maintenance programs rather thanvice versa. In a plant using predictive maintenance, thevice versa. In a plant using predictive maintenance, the

overall machinery condition at any time is known, andoverall machinery condition at any time is known, andmuch more accurate planning is possible.much more accurate planning is possible.

•• Benefits of Predictive MaintenanceBenefits of Predictive Maintenance

– – The major benefit of predictive maintenance ofThe major benefit of predictive maintenance ofmechanical equipment is increased readiness due tomechanical equipment is increased readiness due togreater reliability of the equipment. The trending overgreater reliability of the equipment. The trending overtime of developing faults in machines can be carefullytime of developing faults in machines can be carefullydone so as to plan maintenance operations todone so as to plan maintenance operations to

coincide with scheduled shutdownscoincide with scheduled shutdowns..

SAAT PERAWATAN YANG TEPAT



SAAT PERAWATAN YANG TEPAT

Predictive Maintenance (PdM).Perbaikan tepat pada waktunya

Time based preventive maintenance (PM)

Mesin terlambatdiperbaiki

Perbaikan dilakukanterlalu awal



Predictive Maintenance TechnologiesPredictive Maintenance Technologies

•• InfraredInfrared ThermographyThermography•• Lubrication analysisLubrication analysis

•• Vibration AnalysisVibration Analysis



Energy and Power ConsiderationsEnergy and Power Considerations

•• Energy is required to produce vibration and in the caseEnergy is required to produce vibration and in the case

of machine vibration, this energy comes from the sourceof machine vibration, this energy comes from the sourceof power to the machine. This energy source can be theof power to the machine. This energy source can be theAC power line, an internal combustion engine, or steamAC power line, an internal combustion engine, or steamdriving a turbine, etc. Energy is defined as forcedriving a turbine, etc. Energy is defined as force

multiplied by the distance over which the force acts, andmultiplied by the distance over which the force acts, andthe SI unit of energy is the Joule. One Joule of energy isthe SI unit of energy is the Joule. One Joule of energy isequivalent to a force of one Newton acting over aequivalent to a force of one Newton acting over adistance of one meter. The physical concept of work isdistance of one meter. The physical concept of work is

similar to that of energy, and the units used to measuresimilar to that of energy, and the units used to measurework are the same as those for measuring energy.work are the same as those for measuring energy.



Energy and Power ConsiderationsEnergy and Power Considerations•• The actual amount of energy present in the machine vibration itsThe actual amount of energy present in the machine vibration itselfelf

is usually not very great compared to the energy required to opeis usually not very great compared to the energy required to operateratethe machine for its intended task.the machine for its intended task.

•• Power is defined as the rate of doing work, or the rate of energPower is defined as the rate of doing work, or the rate of energyytransfer, and according to the SI, it is measured in Joules pertransfer, and according to the SI, it is measured in Joules persecond, or Watts. One horsepower is equivalent to 746 watts. Powsecond, or Watts. One horsepower is equivalent to 746 watts. Powereris proportional to the square of the vibration amplitude, just ais proportional to the square of the vibration amplitude, just ass

electrical power is proportional to the voltage squared or the celectrical power is proportional to the voltage squared or the currenturrentsquared.squared.

•• According to the law of conservation of energy, energy cannot beAccording to the law of conservation of energy, energy cannot becreated or destroyed, but it can be transformed into different fcreated or destroyed, but it can be transformed into different forms.orms.

The vibratory energy in a mechanical system is ultimately dissipThe vibratory energy in a mechanical system is ultimately dissipatedatedin the form of heat.in the form of heat.

PROACTIVE MAINTENANCE



O C C

(PREVENTION MAINTENANCE)• Kerusakan premature (belum saatnya) dapat

terjadi atas peralatan

• Mencegah perbaikan berulang atas kerusakanpremature

• Kerusakan jenis tersebut harus dicari

penyebabnya dengan Root Cause FailureAnalysis (RCFA)

• Improvement/redesign komponen dilakukan

berdasar hasil RCFA

Proactive MaintenanceProactive Maintenance



TechnologiesTechnologies•• Dynamic BalancingDynamic Balancing

•• Precision Shaft AlignmentPrecision Shaft Alignment•• Ultrasonic Testing / Air & SteamUltrasonic Testing / Air & Steam

•• Belt / Pulley AlignmentBelt / Pulley Alignment

•• Acceptance TestingAcceptance Testing

•• Water / Air Flow balancing & MeasuringWater / Air Flow balancing & Measuring

•• MeteringMetering

Pro active Maintenance



ProPro

--active Maintenanceactive Maintenance

•• ProPro--active maintenance, which uses a variety ofactive maintenance, which uses a variety oftechnologies to extend the operating lives oftechnologies to extend the operating lives ofmachines and to virtually eliminate reactivemachines and to virtually eliminate reactivemaintenance. The major part of a promaintenance. The major part of a pro--activeactiveprogram is root cause failure analysis (RCA),program is root cause failure analysis (RCA),which is the determination of the mechanismswhich is the determination of the mechanismsand causes of machine faults. The fundamentaland causes of machine faults. The fundamentalcauses of machine failures can thus becauses of machine failures can thus becorrected, and the failure mechanisms can becorrected, and the failure mechanisms can begradually engineered out of each machinerygradually engineered out of each machineryinstallation.installation.

Maintenance Strategy Comparation



Maintenance Strategy Comparation

Heart attack or strokeLarge maintenancebudget

Break down,Run ToFailure,Reactive

By-pass or transplantsurgery

Periodic componentsreplacement

Preventive

Detection of heart disease

by ECG or ultrasonic

Monitoring of vibration,

temperature, alignment,pressure, wear debris

Predictive

Cholesterol and bloodpressure monitoring,followed by diet control

Monitoring andcorrection of “failing rootcauses”

Proactive

Human Health ParallelTechnique NeededMaintenanceStrategy

RCM (Reliability Centered Maintenance)





Reactive,RTF

PM, TimeBased

PdM, ConditionBased, Predictive

Proactive

•Small items

•Non critical

•Inconsequential

•Unlikely to fail

•Redundant

•Subject to wear out

•Consumable

replacement

•Failure pattern known

•Random failure patterns

•Not subject to wear

•PM Induced failures

•Age exploration

•RCFA

•FMEA

•Acceptance testing

RCFA = Root Cause Failure Analysis

FMEA = Failure Mode and Effect Analysis




( y )



RULES FOR BREAKDOWN



MAINTENANCE

• If equipment is redundant

• Low cost spares available

• Interruptible process, stock pile

• Safe failure modes

• Long MTTF/MTBF• Low cost secondary damage

• Quick repair/replacement (low cost of interuption

of production)

RULES FOR PREVENTIVE



MAINTENANCE• Statistical failure rate available• Narrow failure distribution (predictable MTBF)• Maintenance restore full integrity• Single failure mode (known)• Low cost of regular overhaul/replacement

• Unexpected interruption to production isexpensive (scheduled interruption is not so bad)

• Low cost spares available

• Reduced number of breakdown is required• Costly secondary damage



ALIRAN INFORMASIDari mana pekerjaan perawatan bermula?

• Internal (dari dalam department ofmaintenance): tugas preventivemaintenance dan corrective maintenance

• Eksternal (dari luar departemen):permintaan dari manajer produksi,

rehabilitasi

Komponen Penting dalam



Perawatan



Gunung Es Perawatan

Organisasi Perawatan



Organisasi Perawatan

Perawatan Mesin 009

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