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Journal : Jurnal Polimesin

Implementation of total quality management and importance-performance analysis for technical service optimization in a maintenance workshop : a case study of PT XYZ Khadafi, M; Away, Yuwaldi; Dirhamsyah, M
Jurnal Polimesin Vol 23, No 3 (2025): June
Publisher : Politeknik Negeri Lhokseumawe

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30811/jpl.v23i3.6860

Abstract

Customer satisfaction is a key factor of success in service-based industries and is equally important in technical service environments such as PT XYZ’s mechanical repair workshop, which provides civil works, welding, machinery, and valve maintenance services. This study aims to assess service quality and identify the primary factors influencing customer satisfaction, with the objective of formulating strategic improvements tailored to the workshop setting. A quantitative research approach was adopted, incorporating the SERVQUAL dimensions and the Total Quality Management (TQM) framework, while customer loyalty was measured using the Net Promoter Score (NPS). The study involved 93 internal respondents from various organizational units, with work experience ranging from less than five years to more than twenty years. Results indicate a high level of satisfaction, with a Net Promoter Score of 57.29% and an Internal Customer Satisfaction (ICS) Index of 86.9%. Multiple linear regression analysis showed that service quality and Total Quality Management collectively explained 84.3% of the variance in customer satisfaction. Importance and Performance Analysis (IPA) identified education and training, customer focus, and reliability as the top strategic improvement priorities. From an operational perspective, the most frequently requested services included pump shaft fabrication (item code 63-GA-6004, 30 hours), shaft sleeve fabrication (63-GA-6004, 16 hours), and shaft sleeve fabrication (56-GA-4002, initially 36 hours). Following the implementation of these improvements, the workshop achieved a 20 percent reduction in average processing time and completed 182 service activities within two months, significantly enhancing operational efficiency and customer satisfaction.
Reliability enhancement in petrochemical industry: an integrated RBD and FTA approach Ariandi, Teuku; Away, Yuwaldi; Dirhamsyah, Dirhamsyah
Jurnal Polimesin Vol 23, No 4 (2025): August
Publisher : Politeknik Negeri Lhokseumawe

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30811/jpl.v23i4.7210

Abstract

Turnaround maintenance plays an important role in the petrochemical industry, directly influencing production reliability and operational continuity. Unplanned shutdowns and service disruptions can result in significant economic losses, yet statistics show that nearly 80% of turnaround activities fail to achieve their performance targets in terms of time, cost, safety, quality, and environmental compliance. This study addresses these challenges by evaluating and enhancing the reliability of the ammonia production system at an Indonesian petrochemical company through an integrated approach combining the Reliability Block Diagram (RBD) and Fault Tree Analysis (FTA). RBD modeling was used to represent the production system as functionally arranged blocks, while FTA was applied to identify root causes of failures. Analysis using ReliaSoft BlockSim and Weibull++ revealed that the system’s reliability was only 0.029 over 5,000 hours, far below the target reliability of 0.9. The most critical components were identified as the Primary Reformer, Ammonia Compressor, and Syngas Compressor. Seven improvement scenarios were simulated, with results showing that the combination of preventive maintenance (PM) and load-sharing configuration yielded the most effective outcome. This approach improved reliability to 0.076 and availability to 0.812. The results show that a proactive, reliability-based maintenance strategy combined with system redundancy can substantially reduce risks of unscheduled shutdowns, extend turnaround intervals, and improve production uptime. Furthermore, the integrated RBD-FTA approach provides a robust framework for proactively identifying and addressing vulnerabilities in complex petrochemical systems.