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All Journal Jurnal Asiimetrik: Jurnal Ilmiah Rekayasa Dan Inovasi Jurnal Teknologi dan Rekayasa Alat Berat (JTRAB)
Surojo
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 Kerusakan Engine High Blow-by Pressure pada Mesin Diesel Unit Excavator Caterpillar 320GC di PT XYZ Pandhu Khanif Pramudya; Surojo
Jurnal Teknologi dan Rekayasa Alat Berat Vol 3 No 2 (2026): JTRAB Volume 3, No 2, 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.v3i2.23741

Abstract

This study analyzes engine damage characterized by high blow-by pressure on a Caterpillar 320 GC excavator unit operated by PT XYZ. The damage is indicated by reduced engine power (low power), along with the emission of white smoke from the muffler and crankcase breather. The analysis was conducted using several methods, including blow-by pressure measurement, Scheduled Oil Sampling (SOS) analysis, engine disassembly (overhaul), and root cause analysis through fishbone diagrams, 5W+1H method, and fault tree analysis (FTA). The results showed that the blow/-by pressure reached 2.72 inHâ‚‚O, indicating a deteriorated engine condition. Oil analysis (SOS) detected high concentrations of wear metals, particularly iron (Fe) at 97.2 ppm, suggesting severe wear on internal engine components. After the overhaul, significant wear exceeding standard tolerance limits was found on the cylinder liner, piston, and piston rings. The primary cause of the high blow-by pressure was identified as wear on the piston rings, pistons, and cylinder liners due to increased levels of wear metals and oil contamination by fuel (fuel dilution), which reduced lubrication effectiveness. This condition was triggered by several contributing factors, including insufficient operator training, improper maintenance procedures, lack of adequate early detection systems, and extreme working environment conditions. As a result, the engine suffered damage and experienced a significant loss of power. The recommended solutions include replacing the worn components (cylinder liner, piston, and piston rings), improving operator training, and implementing a stricter preventive maintenance schedule to restore engine performance and extend component lifespan.
Co-Authors Felixtianus Eko Wismo Winarto Harjono Nugroho Santosa Pandhu Khanif Pramudya Setiawan, Widia Wirawan Widya Mandala