Perawatan Mesin MS 4102 (Maintenance)

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PERAWATAN MESIN MS-4102 (MAINTENANCE)

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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 built

    drawing Commissioning: pengujian terhadap performance yang

    dijanjikan, base line data. Operation (untuk menghasilkan produk) & Maintenance

    (supaya mesin tetap dapat dioperasikan dengan baik). Decommissioning: untuk menentukan apakah mesin

    sudah 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, memompa

    ban, 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?Kita punya armada motor (untukojek).

    Tujuan komersial: untung rugimerupakan pertimbangan penting.

    Motor harus dijaga supaya tetapproduktif dan tidak rewel.

    Melibatkan banyak orang: perludigaji, perlu koordinasi.

    Inventarisasi: merek motor, tahunpembuatan, jadwalpengoperasian, jadwal perawatan.

  • 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

  • WHAT IS MAINTENANCE?

    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, heat exchanger, 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 mencemari

    lingkungan

  • WHAT IS MAINTENANCE?

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    Waktu

    DenganPM

    Performance Min

    TanpaPM

  • WHAT IS MAINTENANCE?P

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    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 dapatdikerjakan 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 data peralatan, termasuk komponen dan perlengkapannya.

  • WHAT IS MAINTENANCE? Maintenance management: pengelolaan kegiatan perawatan Maintenance planning: perencanaan kegiatan perawatan selama 1

    tahun. Maintenance scheduling: penjadwalan kegiatan perawatan

    selama 1 tahun. Overhaul: membongkar mesin sebagian atau keseluruhan dan

    memperbaikinya supaya diperoleh kondisi sesuai standar. User: pengguna Owner: pemilik Vendor: penyedia alat/mesin Efficiency: running hours / (running hours + down time) Trip: mesin mati secara otomatis karena ada parameter operasi

    (suhu, getaran dll) yang melebihi batas aman. Shut in: mesin dimatikan secara sengaja. Shut down: mesin mati dengan sendiri.

  • WHAT IS MAINTENANCE?

    Maintenance

    Planned maintenance Unplanned maintenance

    Preventive maintenance

    Corrective maintenance Emergency

    maintenance

    Overhaul

    Minor Major

    Shutdown maintenance

    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 kegagalan

    komponen 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%

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    Useful life period

    (wealth cycle)

    Start up cycle

    Break 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 yang saling 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, padasaat masih muda maupunsesudah tua

  • FAILURE PATTERN POPULATION PERCENTAGE

    1

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    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: high

    speed turbine) Waktu untuk perbaikan lama

  • Mesin General Purpose

    Kalau rusak tidak membahayakan Kalau rusak tidak mengganggu proses

    produksi 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 II PERKEMBANGAN

    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 dan reliability lebih

    baik-Keselamatan lebih baik-Kualitas produk lebih baik-Tidak mencemari lingkungan-Umur peralatan lebih panjang-Efektifitas biaya lebih baik

    Generasi kedua-Availability lebih baik-Umur peralatan lebih

    panjang-Efektifitas biaya lebih baik

    Generasi pertama-Perbaiki kalau rusak

    Tuntutanyang sem

    akin meningkat thd

    maintenance

    1940 1950 1960 1970 1980 1990 2000

  • PERKEMBANGAN STRATEGI PERAWATAN

    Generasi ketiga-Pemantauan kondisi mesin-Design for reliability and

    maintainability-Hazard studies-Komputer kecil, cepat-FMEA-Expert systems-Multi tasking and teamworks

    Generasi kedua-Overhaul terjadwal-Sistem utk perencanaan dan

    pengendalian kerja-Komputer besar dan lambat

    Generasi pertama-Perbaiki kalau rusak

    1940 1950 1960 1970 1980 1990 2000

  • PERKEMBANGAN FILOSOFI PERAWATAN

    Break down (run to failure) maintenance : mesindioperasikan tanpa perawatan sampai kerusakan terjadi. Kerusakan primer hampir selalu menimbulkan kerusakansekunder.

    Preventive maintenance (PM) atau time base maintenance: mesin dimaintain secara terjadwalsetelah 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 yang terjadi 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.Emergency outages

    Disadvantages (when implemented correctly)

    Less maintenance required

    Can spot potential failure

    Can be planned for or scheduled

    CheapAdvantages (when implemented correctly)

    Redesign to eliminate root cause of failure

    Maintain based upon known condition/standard

    Conduct maintenance at regular intervals

    Fix it when it breaks, 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 sometimes failure maintenance is sometimes called "crisis maintenance" for good called "crisis maintenance" for good reason. This has been the dominant form reason. This has been the dominant form of maintenance for a long time, and its of maintenance for a long time, and its costs are relatively high because of costs are relatively high because of unplanned downtime, damaged unplanned downtime, damaged machinery, and overtime expenditure. machinery, and overtime expenditure.

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

    Fix it when it breaksFix it when it breaks Run to failureRun 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 Management Work Orders generated Facility Asset Management Information SystemInformation System

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

    "historical" maintenance. This is where the histories of each "historical" maintenance. This is where the histories of each machine type are analyzed and periodic overhauls are scheduled tmachine type are analyzed and periodic overhauls are scheduled to o occur before the statistically expected problems occur. It has loccur before the statistically expected problems occur. It has long ong been known that most groups of similar machines will exhibit faibeen known that most groups of similar machines will exhibit failure lure rates 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 failure called "Bathtub Curve" which relates failure rate to operating time, as follows:rate to operating time, as follows:

  • PREVENTIVE MAINTENANCE (TIME BASED)

    Preventive maintenance adalah suatu tindakan untukmenjaga agar peralatan tetap dapat beroperasi dengancara inspeksi, deteksi dan pencegahan kerusakan.

    Semua kegiatan perawatan dijadwal berdasar waktu(mingguan, bulanan, triwulanan, 1000 jam, 3000 jam dlsb)

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

    Penganggaran mudah: anggaran umumnya dibuattahunan.

  • PREVENTIVE MAINTENANCE (TIME BASED)

    Murphy Law: Kerusakan biasanya terjadi pada waktuperalatan sangat dibutuhkan.

    Contoh: Pada saat banyak order, peralatan produksirusak. Perbaikan dapat memakan waktu beberapa jam atau beberapa hari.

    Hal yang tidak menguntungkan ini dapat dicegah denganPM.

    Alasan lain: keselamatan, penghematan biaya perbaikankarena kerusakan sekunder.

  • PREVENTIVE MAINTENANCE (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 yang buruk.

  • PREVENTIVE MAINTENANCE (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 tanpa

    PM

  • Example 3 pumps of exactly the same type and manufacturer, however, each

    requires different maintenance strategy. Pump A: Preventive maintenance (PM) Pump B: Break down maintenance (RTF) Pump C: Periodic test to eliminate hidden failure or PM

    Pump A (continuous running)

    Pump B (continuous running)

    Pump C (standby, hidden failure)

    100 l/min cooling water

    100 l/min cooling water

    Production Train 1

    Loss USD 200,000./day when stop

    Production Train 1Loss USD 200,000./day when stop

  • Example 3 pumps of exactly the same type and manufacturer Pump A: Predictive maintenance ??? Pump B: Break down maintenance??? Pump C: Periodic test???

    Pump A (continuous running)

    Pump B (continuous running)

    Pump C (standby, hidden failure)

    100 l/min nitric acid

    100 l/min nitric acid

    Production Train 1

    Loss USD 200,000./day when stop

    Production Train 1Loss USD 200,000./day when stop

  • PREVENTIVE MAINTENANCE (TIME BASED)

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    % maintenance delay

    Lebih banyak uang untuk PM, terjadisedikit keterlambatan

    Lebih sedikit uang untuk PM, terjadi banyak keterlambatan

  • PREVENTIVE MAINTENANCE (TIME BASED)

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    Production cost due to delay

    Production cost as affected by maintenance cost

    PM cost#1

    #3

    #2

  • PREVENTIVE MAINTENANCE (TIME BASED)

    #1: terlalu banyak PM, menghamburkan tenaga, sukucadang dan uang.

    #2: sangat kurang, akan terjadi banyak kerusakan #3: sangat optimum, tapi jarang tercapai. Indikasinya

    20% peralatan mengalami kerusakan sebelumdiperbaiki.

    Bila tidak terjadi kerusakan sebelum diperbaiki berartiPM terlalu banyak.

  • PREVENTIVE MAINTENANCE (TIME BASED)

    Rumus empirik untuk menentukan faktor PM (makintinggi nilainya PM makin perlu)

    PM = D(A+B+C)/(EF)PM = inspection factorD = number of break down/yearA = cost of break down repairsB = cost of lost productionC = cost of repairing other equipment involved in the

    breakdownE = cost of PM activity (average)F = number of PM cycle per year

  • PREVENTIVE MAINTENANCE (TIME BASED)

    Do PM (Preventive Maintenance) if number of break down x Average cost per break down x 70% > cost of PM system

  • PREVENTIVE MAINTENANCE (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 machineAnalysisRemove and replace pumpScheduled replacementAdd oilLubricateRead temperature, pressure, vibrationTake readingAdjust tightening boltAdjustingWarming up machine/prepare for operationOperatingTighten anchor boltsTighteningRemove debris from machinesCleaningLook for leak in hydraulic systemInspectionExampleType of Task

  • PREVENTIVE MAINTENANCE (TIME BASED)

    Inspection Memastikan performansi peralatan sesuai perancangan Mengevaluasi semua komponen terhadap masalah yang

    potensial menimbulkan kerusakan Mengidentifikasi komponen yang dapat menyebabkan

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

  • PREVENTIVE MAINTENANCE (TIME BASED)

    Inspeksi dilakukan Karena tuntutan peraturan: Pressure vessel harus

    diinspeksi secara berkala sesuai dengan peraturanpemerintah tentang keselamatan kerja.

    Karena mesin tidak dilengkapi dengan cadangan danberesiko terhadap keberlangsungan proses produksi.

    Pada peralatan yang sedang rusak

  • CORRECTIVE MAINTENANCE (PERBAIKAN) SEBAGAI RESPONS TERHADAP INSPEKSI DALAM PM

    Biaya perbaikan

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  • PREDICTIVE MAINTENANCE (PdM)

    Preventive Maintenance

    Time Based Maintenance

    Predictive Maintenance,

    Condition Based Maintenance

  • Predictive MaintenancePredictive Maintenance Predictive maintenance allows management to control Predictive maintenance allows management to control

    the machinery and maintenance programs rather than the machinery and maintenance programs rather than vice versa. In a plant using predictive maintenance, the vice versa. In a plant using predictive maintenance, the overall machinery condition at any time is known, and overall machinery condition at any time is known, and much more accurate planning is possible.much more accurate planning is possible.

    Benefits of Predictive MaintenanceBenefits of Predictive Maintenance The major benefit of predictive maintenance of The major benefit of predictive maintenance of

    mechanical equipment is increased readiness due to mechanical equipment is increased readiness due to greater reliability of the equipment. The trending over greater reliability of the equipment. The trending over time of developing faults in machines can be carefully time of developing faults in machines can be carefully done so as to plan maintenance operations to done so as to plan maintenance operations to coincide with scheduled shutdownscoincide with scheduled shutdowns..

  • 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

    Infrared Infrared ThermographyThermography Lubrication analysisLubrication analysis Vibration AnalysisVibration Analysis

  • Energy and Power ConsiderationsEnergy and Power Considerations

    Energy is required to produce vibration and in the case Energy is required to produce vibration and in the case of machine vibration, this energy comes from the source of machine vibration, this energy comes from the source of power to the machine. This energy source can be the of power to the machine. This energy source can be the AC power line, an internal combustion engine, or steam AC power line, an internal combustion engine, or steam driving a turbine, etc. Energy is defined as force driving a turbine, etc. Energy is defined as force multiplied by the distance over which the force acts, and multiplied by the distance over which the force acts, and the SI unit of energy is the Joule. One Joule of energy is the SI unit of energy is the Joule. One Joule of energy is equivalent to a force of one Newton acting over a equivalent to a force of one Newton acting over a distance of one meter. The physical concept of work is distance of one meter. The physical concept of work is similar to that of energy, and the units used to measure similar to that of energy, and the units used to measure work 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 itself elf

    is usually not very great compared to the energy required to opeis usually not very great compared to the energy required to operate rate the 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 energy y transfer, and according to the SI, it is measured in Joules per transfer, and according to the SI, it is measured in Joules per second, or Watts. One horsepower is equivalent to 746 watts. Powsecond, or Watts. One horsepower is equivalent to 746 watts. Power er is proportional to the square of the vibration amplitude, just ais proportional to the square of the vibration amplitude, just as s electrical power is proportional to the voltage squared or the celectrical power is proportional to the voltage squared or the current urrent squared.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 dissipated ated in the form of heat.in the form of heat.

  • PROACTIVE MAINTENANCE (PREVENTION MAINTENANCE)

    Kerusakan premature (belum saatnya) dapatterjadi atas peralatan

    Mencegah perbaikan berulang atas kerusakanpremature

    Kerusakan jenis tersebut harus dicaripenyebabnya dengan Root Cause Failure Analysis (RCFA)

    Improvement/redesign komponen dilakukanberdasar hasil RCFA

  • Proactive Maintenance Proactive 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

  • ProPro--active Maintenanceactive Maintenance

    ProPro--active maintenance, which uses a variety of active maintenance, which uses a variety of technologies to extend the operating lives of technologies to extend the operating lives of machines and to virtually eliminate reactive machines and to virtually eliminate reactive maintenance. The major part of a promaintenance. The major part of a pro--active active program is root cause failure analysis (RCA), program is root cause failure analysis (RCA), which is the determination of the mechanisms which is the determination of the mechanisms and causes of machine faults. The fundamental and causes of machine faults. The fundamental causes of machine failures can thus be causes of machine failures can thus be corrected, and the failure mechanisms can be corrected, and the failure mechanisms can be gradually engineered out of each machinery gradually engineered out of each machinery installation.installation.

  • Maintenance Strategy Comparation

    Heart attack or strokeLarge maintenance budget

    Break down, Run To Failure, Reactive

    By-pass or transplant surgery

    Periodic components replacement

    Preventive

    Detection of heart disease by ECG or ultrasonic

    Monitoring of vibration, temperature, alignment, pressure, wear debris

    Predictive

    Cholesterol and blood pressure monitoring, followed by diet control

    Monitoring and correction of failing root causes

    Proactive

    Human Health ParallelTechnique NeededMaintenance Strategy

  • RCM (Reliability Centered Maintenance)

    RCM (Reliability Centered Maintenance)

    Reactive, RTF

    PM, Time Based

    PdM, Condition Based, 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

  • RCM (Reliability Centered Maintenance)

  • 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 is

    expensive (scheduled interruption is not so bad) Low cost spares available Reduced number of breakdown is required Costly secondary damage

  • RULES FOR PREDICTIVE MAINTENANCE

    Expensive/critical machinery Long lead time for replacement (no spares) Uninterruptible process (both regular and unexpected)-

    costly Large/complex machinery Overhaul expensive (need highly trained people) Reduced number of highly skilled maintenance people Cost of monitoring program is acceptable Safety is priority (failure dangerous) Remote/mobile equipment Failure is not indicated by operation degeneration Costly secondary damage

  • ALIRAN INFORMASI

    Dari mana pekerjaan perawatan bermula? Internal (dari dalam department of

    maintenance): tugas preventive maintenance dan corrective maintenance

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

  • Komponen Penting dalamPerawatan

  • Gunung Es Perawatan

  • Organisasi Perawatan