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All Journal Jurnal Asiimetrik: Jurnal Ilmiah Rekayasa Dan Inovasi Jurnal Teknologi dan Rekayasa Alat Berat (JTRAB)
Harjono
Universitas Gadjah Mada
Automotive Engineering Civil Engineering, Building, Construction & Architecture Computer Science & IT Control & Systems Engineering Electrical & Electronics Engineering Engineering Industrial & Manufacturing Engineering Mechanical Engineering

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Inventory Management and Proactive Maintenance to Enhance Operational Efficiency in Excavators: Focus on Common Spare Parts Issues Surojo; Widia Setiawan; Harjono; Nugroho Santosa; Felixtianus Eko Wismo Winarto; Wirawan Widya Mandala
Jurnal Asiimetrik: Jurnal Ilmiah Rekayasa Dan Inovasi Volume 7 Number 1 (2025)
Publisher : Fakultas Teknik Universitas Pancasila

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.35814/asiimetrik.v7i1.7770

Abstract

Effective inventory management and maintenance are critical for the operational efficiency of heavy equipment such as excavators. This study focuses on optimizing spare parts inventory for Cummins diesel engines using the min-max stock method. It aims to improve inventory control by categorizing spare parts into slow-moving, medium-moving, and fast-moving components and addressing maintenance issues that impact performance. The research utilized the min-max stock method to determine optimal inventory levels, ensuring spare parts availability while minimizing holding costs. Key maintenance issues in components such as track shoes, cam shafts, rear shafts, motor starters, and exhaust manifolds were identified through inspections. Advanced diagnostic tools, including vibration analyzers and thermal imaging, were used for proactive maintenance. The study identified critical wear and damage in components like track shoes, cam shafts, and exhaust manifolds, which could lead to equipment failure if not addressed. Implementing the min-max stock method helped reduce stockouts and overstocking, ensuring an optimal balance in inventory. The results demonstrate that integrating the min-max stock method with systematic maintenance practices significantly improves operational efficiency. The use of real-time diagnostic tools enabled early issue detection, reducing downtime and maintenance costs. This study emphasizes the importance of inventory optimization, regular inspections, and timely maintenance interventions for enhancing equipment reliability. Future research should explore predictive maintenance technologies to further refine inventory and maintenance strategies in the heavy equipment sector.
Analisis Efektivitas Pemasangan TREPOS Pada Unit Excavator Kelas 20 Ton Sebagai Upaya Preventive Maintenance Komponen Undercarriage Alva Rizki Amanullah; Harjono; Irfan Bahiuddin; Sugiyanto; Muhamad Sandi Isyanto; Arif Khaerudin; Imam Muslih
Jurnal Teknologi dan Rekayasa Alat Berat Vol 3 No 01 (2026): JTRAB Volume 3, No 1, 2026
Publisher : Department of Mechanical Engineering, Vocational College, Gadjah Mada University.

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.22146/jtrab.v3i01.13811

Abstract

The operational pattern of excavator units, particularly travel duration and frequency, is one of the dominant factors contributing to the increased occurrence of undercarriage component breakdowns. Therefore, a system-based operational control mechanism is required to limit excessive travel operations that do not comply with manufacturer standards. This study aims to analyze the effectiveness of installing an additional controller in the form of a Travel Protection System (TREPOS) in a case study of a 20-ton class excavator as a preventive maintenance strategy to improve the reliability of undercarriage components. The research employs an integrated analytical approach comprising Failure Mode and Effect Analysis (FMEA), PDCA, and PICA, along with a comparative analysis of operational data before and after TREPOS implementation. The results indicate that excessive travel duration and intensity are among the dominant factors causing unscheduled breakdowns in the undercarriage system. The implementation of TREPOS effectively controls the unit’s operational pattern by reducing continuous travel time exceeding 20 minutes and suppressing the occurrence of unscheduled breakdowns during the study period. Furthermore, TREPOS implementation has the potential to extend the service life of undercarriage components by up to 48% for carrier rollers, 42% for track rollers, 33% for sprockets, and 86% for track links, which overall contributes to a reduction in maintenance costs.
Co-Authors Alva Rizki Amanullah Arif Khaerudin Felixtianus Eko Wismo Winarto Imam Muslih Irfan Bahiuddin Muhamad Sandi Isyanto Nugroho Santosa Setiawan, Widia Sugiyanto Surojo Wirawan Widya Mandala