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Wilarso, Wilarso
Sekolah TInggi Teknologi Muhammadiyah Cileungsi
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Optimization of Preventive Maintenance Interval for CMYP Ø50 Guide Bush Based on Wear Progression and Reliability–Maintainability Analysis in Headlining Mold Wijanarko; Wilarso
R.E.M. (Rekayasa Energi Manufaktur) Jurnal Vol 11 No 1 (2026): In Progress
Publisher : Universitas Muhammadiyah Sidoarjo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21070/r.e.m.v11i1.1830

Abstract

Guide brushes in the mold headlining system play a crucial role in maintaining the alignment of mold movement and the stability of forming pressure distribution. Dimensional degradation due to wear on these components causes an increase in clearance that can potentially trigger misalignment and product thickness deviation. This study aims to determine the optimal preventive maintenance interval based on the production cycle through the integration of wear progression analysis, reliability maintainability, and total cost function. The method used is a quantitative approach based on mathematical modeling by utilizing actual production data and component dimension measurements. The wear program is modeled linearly against the number of production cycles, then associated with an increase in clearance, product thickness deviation, and a decrease in component reliability function. Optimization of the replacement interval is carried out by minimizing the total cost function that combines preventive costs and the risk of loss due to quality failure. The results show that the guide bush wear rate is 0.99998 mm/cycle which causes an increase in clearance of up to 1 mm in 25 production cycles. This condition results in a product thickness deviation of ±0.2 mm, which is still within the design tolerance limit. Reliability analysis shows an R value of ≈0.3679 at this interval, with a system availability level of 99.53%. Based on the optimization of the total cost function, the optimal preventive maintenance interval is obtained at 25,000 production cycles, which provides a balance between product quality stability and operational cost efficiency. The contribution of this research lies in the development of an integrative model that links the wear progression of precision components with product quality degradation and risk-based maintenance decisions. This approach provides a more representative analytical framework than conventional operating time-based methods, especially for mold alignment components in the automotive manufacturing industry.
Co-Authors Abda Abda Achmad Husen Afriliyanti, Alfiyah Ahmad Aji Kurniawan Ahmad Faisal Mohamad Ayob Aji Setiawan Alfiyah Afriliyanti Ari Dwi Wibowo Arif Ardianto Asep Dharmanto Asep Dharmanto Asep Saepudin Ashari Imamuddin Aswin Domodite Awang Surya awang surya Azharul, Firmansyah Azziqi, Yusril Zindar Barlan Tahiti Saufa Bayu Hamengku Rizkiansyah Bayu Idianto Bayu Idiyanto Bayu Idiyanto C.W. Mohd Noor Che Wan Mohd Noor Che Wan Mohd Noor Che Wan Mohd Noor Dan Mugisidi Dharmanto, Asep Djoko Wahyu K Domodite, Aswin Fatur Rohim Fauzi Ramdani Firman Firman Gunawan Firman Gunawan Firmansyah Azharul Firmansyah Azharul Fitriaji, Abdul Azis Giardyan Komara Hanifah Syayidah Lutfiyah Hilman Sholih Holyness Nurdin Singadimedja Idris, Mustopa Ika Novalia Saputri Ika Novalia Saputri Ilman Nadif Filsafah Indra Gumilar Irpan Setiawan Iwung Hari Retno Iwung Hari Retno Izar Mahmud Syuhada Jaelani Syurdiansyah Jujun Juniadi Juniadi, Jujun Khoidul Umam M Ali Pahmi M. Tri Maulady Alamsyah Miftahul Imtihan Mohamad Anas Sobarnas Mohd. Yuhazri Yaakob Muhamad Farhan Muhammad Ilham Alhabsyie Muhammad Mujtaba Mujiarto Mujiarto Mujiarto, M. Mupah Rizal Mustopa Idris Mustopa Idris Nandang Imam Santosa Nandang Imam Santosa Nur Rofiq Nurkholis Pamuji Agustiar Ma’sudi1 Pracoyo, Wisnu Rendi Reshudin Retno, Iwung Hari Rizki Rudi Indrawan S.Pd. M Kes I Ketut Sudiana . Saepudin, Asep Sholih, Hilman Solly Aryza Sugiharjo Sulistya Agus Prabowo Surya, Awang Umam, Khoidul Umam Upay Ripa’I Verry Surya Hendrawan Wan Nurdiyana Wan Mansor Wijanarko Wisnu Pracoyo Wisnu Pracoyo Wisnu Pracoyo Yusril Zindar Azziqi