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Fransiskus Tatas Dwi Atmaji
Universitas Telkom
Religion Arts Humanities Civil Engineering, Building, Construction & Architecture Computer Science & IT Control & Systems Engineering Decision Sciences, Operations Research & Management Economics, Econometrics & Finance Education Electrical & Electronics Engineering Engineering Industrial & Manufacturing Engineering Mathematics Mechanical Engineering Social Sciences Transportation Other

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PENERAPAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) PADA PERENCANAAN INTERVAL PREVENTIVE MAINTENANCE DAN ESTIMASI BIAYA PEMELIHARAAN MENGGUNAKAN ANALISIS FMECA ( STUDI KASUS : PT. XYZ ) Wirda Hamro Afiva; Fransiskus Tatas Dwi Atmaji; Judi Alhilman
Jurnal PASTI (Penelitian dan Aplikasi Sistem dan Teknik Industri) Vol 13, No 3 (2019): Jurnal PASTI
Publisher : Universitas Mercu Buana

Show Abstract | Download Original | Original Source | Check in Google Scholar | Full PDF (855.01 KB) | DOI: 10.22441/pasti.2019.v13i3.007

Abstract

PT. XYZ merupakan perusahaan yang bergerak dibidang produksi spare part dan aksesoris otomotif khusunya sepeda motor. Permasalahan yang dihadapi perusahaan yaitu sering terjadinya kerusakan pada mesin CNC Milling A dengan jumlah kerusakan 32 kali selama tahun 2017 hingga 2018. Perusahaan menerapkan kegiatan preventive maintenance dan corrective maintenance namun kegiatan maintenance ini tidak berjalan dengan optimal. Oleh karena itu, dilakukan pengembangan sistem pemeliharaan untuk meningkatkan keandalan mesin. Metode yang digunakan yaitu Reliability Centered Maintenance (RCM) dengan tujuan menentukan interval waktu pemeliharaan dan estimasi biaya pemeliharaan yang efisien. RCM dilakukan dengan menganalisis kegagalan dengan analisis FMECA. Hasil dari analisis ini berupa nilai RPN yang menunjukkan komponen bearing rel, bearing spindle dan selang sebagai komponen kritis pada sistem. Kemudian ditentukan kebijakan maintenance dengan hasil 2 scheduled on-condition task, 2 scheduled restoration dan 2 scheduled discard task dengan interval waktu maintenance sesuai dengan kategori task. Melalui metode RCM, PT.XYZ dapat menghemat biaya pemeliharaan sebesar Rp. 51.800.331
PERENCANAAN PENGELOLAAN SUKU CADANG PADA POMPA PRODUK MENGGUNAKAN RELIABILITY CENTERED SPARES PADA TERMINAL BBM PT. XYZ Zhafran Ega; Judi Alhilman; Fransiskus Tatas Dwi Atmaji
Journal Industrial Servicess Vol 4, No 1 (2018): Oktober 2018
Publisher : Fakultas Teknik Jurusan Teknik Industri Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | Full PDF (310.208 KB) | DOI: 10.36055/jiss.v4i1.4095

Abstract

Perbaikan mesin selalu menghambat laju produksi karena mesin tidak dapat digunakan saat komponen mesin sedang dalam masa perawatan. Seringkali komponen mesin tersebut tidak dapat melanjutkan fungsinya kembali. Penggantian komponen menjadi satu-satunya solusi yang mengakibatkan mesin mengalami waktu henti yang berbanding lurus dengan waktu tunggu kedatangan komponen pengganti. Suku cadang komponen diperlukan untuk menghilangkan waktu tunggu tersebut sehingga produksi dapat langsung dilanjutkan. Reliability centered spares digunakan untuk menghitung jumlah suku cadang yang harus disediakan dalam jangka waktu tertentu. Metode ini dihitung berdasarkan data kerusakan historis suatu komponen yang kemudian dikoversikan menjadi mean time to repair dan mean time between failure masing-masing komponen. Metode poisson process digunakan untuk menghitung hasil akhir dari persediaan suku cadang untuk waktu tertentu.
KATEGORI RISIKO, ESTIMASI UMUR SISA, DAN USULAN JADWAL INSPEKSI PADA STORAGE TANK MENGGUNAKAN METODE RISK-BASED INSPECTION PADA PT. XYZ Nisrina Fathnin; Judi Alhilman; Fransiskus Tatas Dwi Atmaji
Journal Industrial Servicess Vol 4, No 1 (2018): Oktober 2018
Publisher : Fakultas Teknik Jurusan Teknik Industri Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.36055/jiss.v4i1.4092

Abstract

PT.XYZ adalah perusahaan yang menyelenggarakan usaha di bidang energi dan petrokimia. Untuk menyalurkan bahan bakar minyak ke konsumen setiap harinya, PT.XYZ harus mampu menyediakan bahan bakar minyak yang berkualitas baik sehingga dapat memenuhi permintaan konsumen. Atmospheric Storage Tank (tangki timbun) adalah tempat untuk menyimpan produk minyak sebelum produk minyak didistribusikan kepada konsumen. Sangat penting untuk mengetahui umur sisa tangki dan perencanaan jadwal inspeksi tangki agar perawatan yang dilakukan efektif dan efisien. Risk Based Inspection (RBI) adalah suatu metode untuk menentukan rencana inspeksi berupa pemilihan peralatan dan kapan harus diinspeksi berdasarkan risiko kegagalannya. Metode RBI yang digunakan adalah RBI Semi Kuantitatif yaitu metode RBI yang menggabungkan antara RBI kuantitatif dan RBI Kualitatif dengan menggunakan standar API 581. Tujuan dari penelitian ini adalah untuk mengetahui kategori risiko, estimasi umur sisa, dan usulan jadwal inspeksi pada tangki timbun. Dari hasil penelitian dapat diketahui kategori risiko pada tangki timbun adalah rendah. Estimasi umur sisa pada dinding tangki timbun padacourse-1 adalah 66 tahun, course-2 adalah 63 tahun, course-3 adalah 73 tahun, course-4 adalah 390 tahun,course-5 adalah 530 tahun, dan course-6 adalah 626 tahun. Usulan interval inspeksi berdasarkan metode RBI adalah 4 atau 5 tahun.
ANALISIS UMUR OPTIMAL DAN JUMLAH OPTIMAL MAINTENANCE SET CREW POMPA PRODUKSI DENGAN MENGGUNAKAN METODE LIFE CYCLE COST (LCC) PT. XYZ Oktaria Tyas Pambayun; Judi Alhilman; Fransiskus Tatas Dwi Atmaji
Journal Industrial Servicess Vol 4, No 1 (2018): Oktober 2018
Publisher : Fakultas Teknik Jurusan Teknik Industri Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.36055/jiss.v4i1.4084

Abstract

PT. XYZ merupakan salah satu perusahaan yang bergerak dalam bidang energi meliputi minyak, gas, serta energi terbarukan. Salah satu peralatan yang menunjang dalam kegiatan penyaluran bahan bakar minyak yaitu pompa produksi. Pompa produksi memiliki fungsi penting yaitu untuk mengirimkan atau menyalurkan bahan bakar minyak dari tangki timbun menuju ke bagian pengisian mobil pendistribusian bahan bakar minyak. Salah satu cara yang dapat digunakan untuk memastikan kinerja pompa produksi berfungsi, yaitu dengan melakukanmaintenance (perawatan) secara berkala untuk mencegah terjadinya kerusakan ataupun mengatasi kerusakan yang terjadi. Jika pompa produksi mengalami kerusakan maka maintenance set crew yang memperbaiki kerusakan tersebut. Jumlah maintenance set crew dapat mempengaruhi durasi perbaikan. Penentuan jumlahmaintenance set crew yang optimal sanagt dibutuhkan agar perusahaan tidak mengalami kehilangan potential revenue dan biaya labor maintenance yang besar dengan menggunakan metode Life Cycle Cost (LCC) terendah. Metode LCC merupakan pendekatan total biaya yang dikeluarkan dari awal hingga akhir dengan mempertimbagkan beberapa biaya seperti maintenance cost, operating cost, shortage cost, population cost, danpurchasing cost. Pada penelitian ini jumlah optimal maintenance set crew sebanyak satu set crew yang terdiri dari dua tenaga kerja dengan umur optimal pompa produksi selama dua uluh tiga tahun pemakaian.
Pengukuran dan analisa efektivitas mesin pencetak paving menggunakan metode overall equipment effectiveness (OEE) Indira Kusuma Wardani; Fransiskus Tatas Dwi Atmaji; Judi Alhilman
Journal Industrial Servicess Vol 7, No 1 (2021): Oktober 2021
Publisher : Fakultas Teknik Jurusan Teknik Industri Universitas Sultan Ageng Tirtayasa

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.36055/jiss.v7i1.12336

Abstract

Machine effectiveness is one of the important factors in the production process in a manufacturing company to produce goods. The paving molding machine is one of the machines used to produce black paving at PT XYZ. Based on historical data from the Engineering Maintenance Department, this machine has the highest breakdown frequency which has an impact on the low effectiveness and productivity of the machine. To overcome this problem, an analysis of the effectiveness of the paving molding machine was carried out using the Overall Equipment Effectiveness (OEE) method. OEE aims to analyze machine indicators, which consist of machine availability, performance efficiency, and the quality level of the machine's production. The results of the OEE analysis show that the value of the paving molding machine is 68.18% and is still below the Japan Institute of Plant Maintenance standard of 85%. Six Big Losses is used to determine the low OEE value arising from the production process, on the paving molding machine. From the results of the analysis, two dominant loss factors have the most influence on the effectiveness of the paving molding machine, namely the high value of reduced speed loss (51.92%) and idling and minor stoppages loss (23.69%). These two dominant loss factors are then analyzed using a fishbone diagram to obtain the root causes and proposed solutions.
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

Abstract

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

Abstract

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

Abstract

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

Abstract

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.
Analisis Performansi Nakayama Plant Menggunakan Metode Ramd di PT XYZ Sheila Sekar Soka; Fransiskus Tatas Dwi Atmaji; Marina Yustiana Lubis
Jurnal Teknik Vol 19 No 2 (2021): Jurnal Teknik
Publisher : Universitas Negeri Gorontalo

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37031/jt.v19i2.180

Abstract

PT XYZ is one of the manufacturing industries engaged in the manufacture of spare parts on a national scale. One of the products produced by PT XYZ is magnifold intake pipe which is made in nakayama plant. Based on data from nakayama plant obtained system breakdown structure of the system namely Sand Core, Furnace Gravity, Finishing, Machining, Leaktest. Of the five subsystems will be selected critical subsystems based on the results of RAMD analysis. The result of the data processing that has been done is known that the Reliability value of the system at the time of t = 8 hours is 63.92%. Availability markov process value is 98.546%. The average value of Maintainability at the time of t = 8 hours is 98.951%. The lowest Dependability and Dependability Ratio values are in the Gravity Furnace subsystem with values of 95.634% and 131.759. Therefore, it can be known that the critical subsystem in the system is gravity furnace so it needs to be maintained regularly and scheduled.
Co-Authors Achmad Rizaldi Utomo Adi Riyanto Afiva, Wirda Hamro Agus Kusnayat Aji Pamoso Aldi Bastian Amelia Kurniawati Anak Agung Ngurah Ananda Dwi Rahmawati Anna Annida Noviyanti Annisa Prias Maysarah Anselvi Mega Lestari Arvindha Ramaditya Astri Merlina Bambang Tejo Kusumo Bina Wiraty Hasibuan Cahya Wulan Jayaningrum Citra Andriyadi Dena Aprima Diputra Diansah Hidayat Dida Diah Damayanti Dio Taqiy Asyrof Donni Arisugewo Donny Verryrianto Sidabutar Endang Budiasih Evan Suryatyasto Sujatman Fajar Asyiraq Tilammura Fathnin, Nisrina Fididio Agoeng Pamboedi Ganjar Alfian Gita Ayu Dinar Pramesti Harits Dzulyaddain Harwinvania Fauzia Herlambang Prasetyo Nugroho Husni Amani I Gede Oka Mahendra Ida Bagus Wasudewa Ida Bagus Yoga Samkhyaita Ilham Meiriza Indira Kusuma Wardani Irfan Akmal Diastyono Isna Jihan Navi`a Jasmine Raisya Salsabila Jongtae Rhee Judi Alhilman Judi Alhilman Judi Alhilman Judi Alhilman Judi Alhilman Judi Alhilman, Judi Lalu Galeh Inggil Fatristya Laras Ati Lellyta Nurani P Lestari Atika Putri Liza Nafiah Maulidina Liza Nafiah Maulidina Lukman Subekti Marina Yustiana Lubis Maulidina, Liza Nafiah Muhammad Bangkit Hidayanto Muhammad Irfan Syahputra Hadiyat Muhammad Kamal Fikri Muhammad Siddiq Muthi Maisa Zulfatri Nisrina Fathnin Nopendi Nopendi Nopendri Nopendri Noviyanti, Anna Annida Nurdinintya Athari Supratman Nurul Sholihah Ekowati Oktaria Tyas Pambayun Pratya Poeri Suryadhini Putra Fajar Alam Putri Rahma Muliawati Rachmatul Baety Rayinda Pramuditya Soesanto Rd. Rohmat Saedudin Redi Ahmad Putra Nuranto Riztan Anggitya Sihombing Salsabila, Jasmine Raisya Sandika Lafaldi Sugani Shabrina Zatalini Kuswardani Sheila Amalia Salma Sheila Sekar Soka Syavira Ramadianti Tegar Tri Nugraha Triana Suryani Utama Putra (Telkom University), Anak Agung Ngurah Nanda Valinouski Aulia Widia Juliani Wirda Hamro Afiva Wirda Hamro Afiva Yuris Mulya Saputra Zhafran Ega