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USULAN INTERVAL PREVENTIVE MAINTENANCE DAN ESTIMASI BIAYA PEMELIHARAAN MENGGUNAKAN METODE RELIABILITY CENTERED MAINTENANCE DAN FMECA Afiva, Wirda Hamro; Atmaji, Fransiskus Tatas Dwi; Alhilman, Judi
Jurnal Ilmiah Teknik Industri Vol. 18, No. 2, Desember 2019
Publisher : Muhammadiyah University Press

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.23917/jiti.v18i2.8551

ABC is a company engaged in the production of automotive spare parts and accessories, especially motorcycles. The problems faced by the company, there is frequent damage to the CNC Milling A. The company applies preventive maintenance and corrective maintenance activities, but these maintenance activities have not yet run optimally. Therefore, a maintenance system is developed to improve machine reliability. The method used is Reliability Centered Maintenance (RCM), with the aim of determining the optimal maintenance interval and estimation of efficient maintenance costs. RCM is done by analyzing the Failure Modes Effect and Critical Analysis (FMECA). The results of the FMECA analysis are in the form of a Risk Priority Number (RPN) that shows the components of rail bearings, spindle bearings, and hoses as critical components of the system. Through the RCM method, the maintenance policy is generated in the form of 2 scheduled on-condition tasks, 2 scheduled restorations, and 3 scheduled discard tasks with maintenance time intervals in accordance with the task category and can save maintenance costs of IDR 175.602.300.

Maintenance Cost Analysis Using Cost of Unreliability (COUR) Method with Business Consequence Analysis : A Case Study of Shot Blast Machine Salsabila, Jasmine Raisya; Atmaji, Fransiskus Tatas Dwi; Pamoso, Aji
Jurnal Ilmiah Teknik Industri Vol. 19, No. 02, December 2020
Publisher : Department of Industrial Engineering Universitas Muhammadiyah Surakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.23917/jiti.v19i2.11961

Losses caused by unreliable machines in a production line will affect the total cost losses from a manufacturing company's production process. Based on historical data of damage that has been obtained from the maintenance department of XYZ companies, the MACH MWJ 9/10 Shot Blast Machine is the machine that has the highest-level frequency of damage. This machine is useful for cleaning sand or residual production dirt that sticks to workpieces that have been cast in the casting process, especially for E-Clips components. The research's purpose is to determine the value of cost losses due to machine unreliability using the Cost of Unreliability (COUR) method, with Business Consequence analysis (BC) analysis. The cost effects of these costs include Corrective COUR and Downtime COUR. The final calculation of COUR shows that the total cost of COUR Downtime caused by the unreliability of the machine is greater than the total Corrective COUR. After calculating the COUR, an analysis of the business consequences resulting from the machine's unreliability is carried out using a risk matrix. The analysis results show that the shot blast machine's critical components are in the red or high-risk category and have a very high Probability of Failure (PoF). The results of COUR analysis with business consequence analysis will be an input for the company to make a machine maintenance system policy, especially for the MACH MWJ 9/10 Shot Blast machine's critical components. In general, this research's novelty is to combine the application of the Cost of Unreliability method with an analysis of the effects of the Business Consequence caused by the machine's selected critical components.

Reliability, Availability, Maintainability, and Safety Analysis of Finger Joint Fu-King Furnimate Machine in Wood Manufacturing Industry Tegar Tri Nugraha; Fransiskus Tatas Dwi Atmaji; Sheila Amalia Salma
Jurnal Ilmiah Teknik Industri Vol. 20, No. 2, December 2021
Publisher : Department of Industrial Engineering Universitas Muhammadiyah Surakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.23917/jiti.v20i2.15591

The objective of this research was to investigate the performance of the Finger Joint Fu-King Furnimate machine, especially for the most critical component of this machine. Based on historical data of machine damage, the Finger Joint Fu-King Furnimate is the machine that has the highest-level frequency of damage. Reliability, Availability, Maintainability, and Safety (RAMS) methods are proposed to analyze the machine's historical data. The result shows that the reliability of machine performance at t = 160 hours is only 27.42%, but the availability of machines is quite high, which passed the standard of 95%. Meanwhile, the maintainability of the machine is relatively fast, which the repair time of its critical component is 8 hours. The low-reliability critical machine spare part affected the safety of the spare part which the Safety Integrity Level (SIL) in the lowest standard (level 1). In general, the novelty of this research is to combine the application of the RAM method as the basis for analyzing machine performance with a safety analysis of the selected critical machine subsystems.

Maintenance Cost Analysis Using Cost of Unreliability (COUR) Method with Business Consequence Analysis : A Case Study of Shot Blast Machine Jasmine Raisya Salsabila; Fransiskus Tatas Dwi Atmaji; Aji Pamoso
Jurnal Ilmiah Teknik Industri Vol. 19, No. 02, December 2020
Publisher : Department of Industrial Engineering Universitas Muhammadiyah Surakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.23917/jiti.v19i2.11961

Losses caused by unreliable machines in a production line will affect the total cost losses from a manufacturing company's production process. Based on historical data of damage that has been obtained from the maintenance department of XYZ companies, the MACH MWJ 9/10 Shot Blast Machine is the machine that has the highest-level frequency of damage. This machine is useful for cleaning sand or residual production dirt that sticks to workpieces that have been cast in the casting process, especially for E-Clips components. The research's purpose is to determine the value of cost losses due to machine unreliability using the Cost of Unreliability (COUR) method, with Business Consequence analysis (BC) analysis. The cost effects of these costs include Corrective COUR and Downtime COUR. The final calculation of COUR shows that the total cost of COUR Downtime caused by the unreliability of the machine is greater than the total Corrective COUR. After calculating the COUR, an analysis of the business consequences resulting from the machine's unreliability is carried out using a risk matrix. The analysis results show that the shot blast machine's critical components are in the red or high-risk category and have a very high Probability of Failure (PoF). The results of COUR analysis with business consequence analysis will be an input for the company to make a machine maintenance system policy, especially for the MACH MWJ 9/10 Shot Blast machine's critical components. In general, this research's novelty is to combine the application of the Cost of Unreliability method with an analysis of the effects of the Business Consequence caused by the machine's selected critical components.

An Autonomous Maintenance Design Based on Overall Resource Effectiveness (ORE) Analysis: A Case Study of Paving Molding Machine Indira Kusuma Wardani; Fransiskus Tatas Dwi Atmaji; Judi Alhilman
Jurnal Ilmiah Teknik Industri Vol. 20, No. 2, December 2021
Publisher : Department of Industrial Engineering Universitas Muhammadiyah Surakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.23917/jiti.v20i2.15627

The paving molding machine is one of the machines used to produce black paving at PT XYZ. Based on the historical data from the engineering maintenance department, this machine has the highest breakdown frequency which affected the low performance and productivity of the machine. To solve this problem, the effectiveness of the paving molding machine was analyzed using overall resource effectiveness (ORE) methods. ORE aims to analyze machine indicators, consisting of readiness, availability of the facility, changeover efficiency, availability of material, availability of manpower, performance efficiency, and quality rate. The ORE analyzed result shows that values of performance efficiency of paving molding machine were 64.54% and still below the standards of the ORE. To increase the ORE, a design of autonomous maintenance (AM) was proposed. The proposed design means the operator is given the responsibility to maintain the basic condition of the machine to minimize the damage of the paving molding machine at PT XYZ. The result of ORE analysis, especially in the performance efficiency, will be an input for the engineering maintenance department to make an AM basic design that can be executed by each of the machine's operators. In general, this research’s novelty is to combine the application of the ORE method with the AM basic design, whereas the AM is one of the pillars of total productive maintenance (TPM).

Usulan Interval Preventive Maintenance dan Estimasi Biaya Pemeliharaan Menggunakan Metode Reliability Centered Maintenance dan FMECA Wirda Hamro Afiva; Fransiskus Tatas Dwi Atmaji; Judi Alhilman
Jurnal Ilmiah Teknik Industri Vol. 18, No. 2, Desember 2019
Publisher : Department of Industrial Engineering Universitas Muhammadiyah Surakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.23917/jiti.v18i2.8551

ABC is a company engaged in the production of automotive spare parts and accessories, especially motorcycles. The problems faced by the company, there is frequent damage to the CNC Milling A. The company applies preventive maintenance and corrective maintenance activities, but these maintenance activities have not yet run optimally. Therefore, a maintenance system is developed to improve machine reliability. The method used is Reliability Centered Maintenance (RCM), with the aim of determining the optimal maintenance interval and estimation of efficient maintenance costs. RCM is done by analyzing the Failure Modes Effect and Critical Analysis (FMECA). The results of the FMECA analysis are in the form of a Risk Priority Number (RPN) that shows the components of rail bearings, spindle bearings, and hoses as critical components of the system. Through the RCM method, the maintenance policy is generated in the form of 2 scheduled on-condition tasks, 2 scheduled restorations, and 3 scheduled discard tasks with maintenance time intervals in accordance with the task category and can save maintenance costs of IDR 175.602.300.

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