Reliability Centered Maintenance Method Research Articles

Optimization of preventive maintenance on critical machines at the Sabiz 1 plant using Reliability-Centered Maintenance method

Optimization of preventive maintenance on critical machines at the Sabiz 1 plant using Reliability-Centered Maintenance method

Reliability Centered Maintenance Method on Quotient Gradient System (QGS) in Production at PT ABC Dumai

QGS A1 is a powerful crusher and dryer designed based on reference drying equipment with good performance efficiency. QGS A1 has a very important function in expediting the production process, but this tool often breaks down so it really affects the smooth production. In connection with the damage to the tool needs to be examined to find out what maintenance should be done.This study aims to find out earlier the damage that affects the smooth production so that it can be known what maintenance actions must be carried out . This study uses the Reliability Centered Maintenance method which utilizes information on reliability and weaknesses as well as maintenance actions to choose from. The results of this study found a solution that the QGS A1 treatment run to failure was 81.2%, direct condition was 18.18%, and failure finding was 0%. The conclusion of this study is Condition Directed, namely the actions taken aim to detect damage by visual inspection, checking tools and monitoring a number of existing data.

Analisis Perawatan Mesin Kapal dengan Metode Reliability Centered Maintenance (RCM) di PT Jasa Armada Indonesia Tbk

Maintenance of the ship is a task aimed at ensuring that the ship continues to operate in a normal and seaworthy condition. This work is related to the ship's machinery system and other equipment on board. If the ship does not receive regular maintenance, it can impact the condition and performance of the ship. By implementing Reliability Centered Maintenance (RCM), information about the steps needed to ensure optimal operation of the engine or equipment can be obtained. RCM is a method used to develop Preventive Maintenance. In Time Directed (TD), there are two components, namely the schottel Asd component and the valve on the cylinder head. In Condition Directed (CD), there are three components found in the three pipe components: fuel pipe, oil, and engine coolant. In Failure Finding (FF), there are four components found in the seachast component, injector pump, fuel filter, and air. Based on the application of the RCM method used, the recommended maintenance actions for the Finding Failure (FF) category include daily, weekly, and monthly inspection activities. Meanwhile, for the Time Directed (TD) category, maintenance actions involve scheduling component replacements based on predetermined intervals. Keywords: FMEA, LTA, Maintenance, RCM

Application of the Reliability Centred Maintenance Method at QGS in PT ABC Dumai

QGS A1 is a powerful crusher and dryer designed based on reference drying equipment with good performance efficiency. It has a very important function in expediting the production process, but this tool often breaks down, which really affects smooth production. In connection with the damage to the tool, it needs to be examined to find out what maintenance should be done. This study aims to find out earlier the damage that affects the smooth production so that it can be known what maintenance actions must be carried out. This study uses the Reliability-Centered Maintenance method, which utilizes information on reliability and weaknesses as well as a list of maintenance actions to choose from. The results of this study found a solution: the QGS A1 treatment run to failure was 81.2%, the direct condition was 18.18%, and the failure finding was 0%.

Analisis interval waktu perawatan preventif pada Paper Machine dengan metode reliability centered maintenance (RCM)

The maintenance process and preventive measures on paper machines need to be studied further, this will affect the production process and paper machine performance. This study aims to determine the criticality of the drying machine failure and determine the preventive measures that must be taken in the maintenance of the dryer and determine the time interval for the maintenance of the dryer machine components. To overcome this problem, this research was made using the Reliability Centered Maintenance (RCM) method. RCM can be interpreted as a process used in determining what to do for the machine, wherein in the RCM methodology there is one FMEA calculation in dealing with critical components in the dryer. Based on data processing and analysis using the RCM method, the maintenance time interval results from the maintenance of the dryer component. The results found are drums/cylinders with maintenance intervals of 82.7 hours, components of all pipes with maintenance intervals of 91.1 hours, and gear components with maintenance intervals of 110.7 hours. The implications for the company's factory regarding preventive maintenance intervals will have an impact on improving the production process and performance of paper machines through early prevention of machine failures that often occur.

Electric power distribution maintenance model for industrial customers: Total productive maintenance (TPM), reliability-centered maintenance (RCM), and four-discipline execution (4DX) approach

The reliability of the electric power distribution system is crucial for industrial consumers, particularly in Karawang Regency, one of the industrial centers in Indonesia. The management of electricity supply for industries in Karawang Regency is entrusted to the Indonesian State Electricity Enterprises, also known as PLN. However, there are still disturbances in the distribution system that affect industrial customers. The primary causes of these disturbances are 39% jointing damage, 36% damage caused by third parties, and 15% damage to cubicles. The occurrence of these disturbances is closely tied to maintenance activities on the electric power distribution system. To assess the distribution system's reliability, various indices are calculated, including the System Average Interruption Frequency Index (SAIFI), System Average Interruption Duration Index (SAIDI), energy not supplied (ENS), and feeder disturbance indices. Currently, PT PLN (Persero) UP3 Karawang employs a maintenance model that combines corrective and preventive methods with the four-discipline execution (4DX) approach. This study aims to develop an improved maintenance model that enhances the overall performance of the electric power distribution system for industrial customers. In this study, a maintenance model is proposed by integrating the total productive maintenance (TPM) method, reliability-centered maintenance (RCM) method, and four-discipline execution (4DX) approach. The developed maintenance model is tested on 40 feeders serving industrial customers. A comparative analysis is performed before and after implementing the maintenance model, considering the SAIFI, SAIDI, ENS, feeder disturbance, and overall equipment effectiveness (OEE) indexes. The analysis of the 40 feeders reveals improvements in performance following the implementation of the maintenance model using the TPM, RCM, and 4DX methods. Prior to implementation, the SAIFI was 0.24 times/cust.yr, SAIDI was 1.877 min/cust.yr, ENS was 60,470 kWh, feeder disturbance occurred 8 times, and OEE was 0.99935. After implementation, the SAIFI improved to 0.016 times/cust.yr, SAIDI reduced to 1.342 min/cust.yr, ENS decreased to 41,241 kWh, feeder disturbance reduced to 4 times, and OEE increased to 0.99962. Consequently, the performance improvements are as follows: SAIFI by 33%, SAIDI by 29%, ENS by 32%, feeder interference by 50%, and OEE by 0.027%.

Reliability and Risk Centered Maintenance: A Novel Method for Supporting Maintenance Management

Proper maintenance planning is critical for maintenance management to contribute to increasing availability, ensuring quality requirements, and controlling the safety and environmental risks associated with physical assets. As supporting tools for developing maintenance strategies, Reliability-Centered Maintenance (RCM) and Risk-Based Maintenance (RBM) methods are currently used in several organizations. Nevertheless, these strategies are often approached separately although they are complementary. In this context, this paper proposes a novel method that effectively integrates RCM and RBM by adapting the traditional RCM method to incorporate risk management into maintenance planning decision-making to support maintenance management. The proposed Reliability and Risk Centered Maintenance (RRCM) method allows organizations to determine maintenance plans that ensure the reliability of the physical assets while considering and prioritizing the risks associated with their potential functional failures. The proposed method was demonstrated through a case study considering the operational context of a hydroelectric power plant. The results show the ability of RRCM to assist in the development and implementation of maintenance plans oriented to reliability, risk, and cost.

Perencanaan Perawatan Motor Penggerak Wesel Type T84M dengan Menggunakan Metode RCM (Reliability Centered Maintenance) di Daop 2 Bandung

Daop 2 Bandung is one of the train operational areas where each station has a signaling system to maintain safety and regulate train operations so that they remain effective and efficient. This research aims to determine the maintenance planning system for the Type T84M Wesel Drive Motor using the RCM (Reliability Centered Maintenance) method in Daop 2 Bandung. The method used is RCM (Reliability Centered Maintenance) which focuses on secondary data in the form of historical data on disturbances on the T84M draft motorbike which is used to calculate maintenance time intervals based on the results of data distribution for each component according to the RCM (Reliability Centered Maintenance) method. The research results show that the appropriate maintenance tasks for wesel motor components are scheduled disposal tasks and scheduled restoration tasks. The T84M draft motorbike has a reliability value of 43.2% and an availability value of 99% and the recommended maintenance interval for the T84M draft motorbike is 3 days.

IMPLEMENTASI METODE RELIABILITY CENTERED MAINTENANCE PADA KOMPONEN KRITIS TURBIN UAP DI PT MADUBARU

IMPLEMENTATION OF RELIABILITY CENTERED MAINTENANCE METHOD ON CRITICAL COMPONENTS OF STEAM TURBINE AT PT MADUBARUSteam turbine is a machine that can be used to convert heat energy from steam into mechanical energy so that it can produce electrical energy. As a source of electrical energy, PT Madubaru utilizes this steam turbine. The purpose of this research is to determine the Mean Time To Failure or MTTF and Mean Time To Repair or MTTR values and which components of this steam turbine have the highest Risk Priority Number (RPN) based on FMEA analysis. This study uses FMEA analysis and the Reliability Centered Maintenance (RCM) method. From the results of data processing that has been done it is known that the most critical component is the coupling component with a damage percentage level of 21.62% of the other components. Based on the calculation of the MTTF value, the result is 1863.74, this means that the coupling component needs to be maintained or checked after operating for 1863.74 hours or around 77,656 days. In addition, for the calculation of the MTTR value, the result is 0.7941 hours, which means that the coupling component takes 0.7941 hours to repair. While the FMEA analysis showed that the coupling component received the highest RPN value of 24 out of the other components. The cause that occurred was due to a broken coupling membrane which hampered the production process because it was necessary to repair the component.

Failure Analysis of Induced Draft Fan Bearing in PT Semen Padang Using The RCM Method

The development of the technology is getting trigger competition in industri. To compete, companies should can provide products and the quality of services best for consumer. This study aims to find out the causes of bearings that are damaged in the Induced Draft Fan (IDF Bearing) and how to plan strategic maintenance of IDF Bearing. The method used is reliability centered maintenance (RCM). The causes of bearing damage are analyzed using the Failure Mode Effect and Critical Analysis (FMECA) method. The results of this study show that the cause of IDF Bearing damage is clearance with an RPN value of 210, lubrication system with an RPN value of 36, unbalance with an RPN value of 72, and high temperature with an RPN value of 54. Scheduled Restoration Maintenance is applied for IDF Bearing , where task or preventive maintenance in the form of oil change with a time of 5803.2 hours or 241 days.

ANALISIS PERAWATAN MESIN POMPA SENTRIFUGAL DENGAN METODE RELIABILITY CENTERED MAINTENANCE

The pump is an energy conversion machine that can move fluid from one place to another through a piping medium by adding energy to the fluid being moved continuously. To find out or minimize the occurrence of pump damage, periodic maintenance is carried out. In the pump type 6P-4021-J which is used in the STG (Steam Turbine Generator) and BB (Coal Boiler) sectors, PT. PUSRI is affected by the dirty condition of the slurry caused by the presence of mud and other so the working efficiency of the pump decreases. Therefore, periodic and routine maintenance or cleaning is required. Maintenance policies that are corrective or reactive, systematic or scheduled, and Condition-Based, all aim to achieve the availability and reliability of equipment and systems by reducing maintenance costs. Reliability Centered Maintenance method is used to analyze the causes of failure with the results of decisions for system maintenance. The critical components of a centrifugal pump include; bearings, seal rings, and impellers. The highest RPN value is the bearing component of 96. The reliability value of the bearing component is 0.468 with an average repair time of 3.32 hours. The recommended maintenance action is to apply lubricant regularly. So that it can reduce wear, prevent corrosion, and control the temperature of the bearing.

Analisa Perawatan Mesin Inflassion dengan Metode Reliability Centered Maintenance

Failure can affected production activities and increase product defects. In addition, damage to the machine can result in high maintenance costs and decreased reliability and availability of the machine. PT. Fujisei Metal Indonesia is a manufacturing company that produces evaporator products. In the process, the inflation machine on the rollbound line is often damaged. The purpose of this study was to determine the critical components of the inflation engine and to reduce maintenance costs on the inflation engine. The method used in this study is the Reliability Centered Maintenance Method so that it can reduce maintenance costs by 26%.

Development of Optimized Maintenance Program for a Steam Boiler System Using Reliability-Centered Maintenance Approach

Reliability centered maintenance (RCM) is a new strategic framework for evaluating system maintenance requirements in its operating conditions. Some industries employ predictive maintenance strategies in addition to preventive maintenance (PM) strategies, which increase production costs. As the breakdown maintenance (BDM) technique is used, the maintenance cost increases. The RCM approach is a mixture of these maintenance strategies that can be used to optimize the maintenance costs and to ensure the availability of the system. The RCM method was applied to the steam boiler system used in the textile industries for the research work reported in this paper. The RCM methodology stated in the literature cannot be implemented, as it is in Indian textile industries due to the lack of knowledge of RCM principles, a labor-oriented nature, the use of partially computerized information systems, an inadequate maintenance database, and information about maintenance costs and production loss. To resolve these issues, a modified RCM approach involving a large number of experts is developed. To apply this RCM methodology, critical components are identified through reliability and failure mode effect and criticality analysis (FMECA). Finally, scheduled maintenance strategies and their intervals are recommended to ensure that the system continues to operate properly. According to this study, implementing the RCM technique effectively will increase boiler system reliability and availability by 28.15 percent and 0.16 percent, respectively. Additionally, up to 20.32 percent of the maintenance cost can be saved annually by applying these scheduled maintenance programs.

PENENTUAN INTERVAL WAKTU PERAWATAN MESIN INJECTION MOULDING MENGGUNAKAN METODE RCM DI PT “X”

In the industrialized world, product is the main of a production process that forms a production process system. In order to a system of production process running continuesly, need a maintenance of the equipment and production machines. The machine maintenance is needed to minimize the damage of machine then the machine can be used for a long time. The purpose of the study is to calculate the reliability value in which the interval time of maintenance will be determined so that it can support the reliability of the tool. Method of the study uses the RCM (Reliability Centered Maintenance) to solve machine maintenance problems that often occur at PT “X”. RCM method has the advantage of defining a machine focused maintenance program and avoids unnecessary maintenance activities by specifying appropriate maintenance intervals. This study also presents qualitative data in the form of FMEA analysis (Failure Mode Effect Analysis) and quantitative data in the form of determining reliability values and determining maintenance time intervals which provide a solution for PT. “X”.The result of the study, reliability value of the MJM-JLB-HQ Injection Moulding Machine is 0.9183 at 12 hours, VICTOR Injection Moulding is 0.9243 at 4 hours, and the reliability value of MJM-JLB 198-HQ Mould is 0.5125 at 96 hours, VICTOR's Mould is 0.5063 at 72 hours. For the results of maintenance interval to keep the value of reliability not going down below 0.9 is 12 hours for MJM-JLB198-HQ Injection Molding Machines, then 4 hours for VICTOR Injection Moulding Machines. The result maintenance interval analysis of mould with reliability not going down below the value of 0.5 is 96 hours on MJM-JLB198-HQ Injection Moulding Machine, and 72 hours at VICTOR Injection Moulding Machine.

The Maintenance Task Allocation Analysis in Steam Power Plant: Case Study on Closed Cooling Water System

The closed cooling system is one of the systems that functioned to ensure the cooling water supply can be continuously distributed and ensure that the production process does not cause the equipment or products to overheat, which can result in failure to the equipment and affect the production process due to downtime repair. Reliability Centered Maintenance (RCM) is one of the methods that can be used to analyze the cause of failure, impact, and determination of appropriate and effective maintenance tasks. The purpose of this research is to identify potential failures, determine the maintenance task and determine the optimal maintenance schedule in the closed cooling system of a steam power plant by using the Reliability Centered Maintenance method. The results of analysis on the closed cooling pump, heat exchanger, expansion tank, minimum flow valve, and level control valve obtained a total of 155 failure modes, of which 73% of total failure modes were identified as an evident failure and 27% identified as a hidden failure. While the results of the maintenance task recommendation obtained a total of 155 maintenance tasks which consists of 5 maintenance task categories. They are 88 (57%) of total failure modes recommended to scheduled on condition task, 38 (24%) scheduled restoration task, 20 (13%) scheduled discard task, 3 (2%) schedule finding failure, and 6 (4%) of total failure modes recommended to no scheduled maintenance.

ANALISIS PENERAPAN PERAWATAN MOTOR KONVEYOR MESIN XRAY DENGAN MENGGUNAKAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) PADA PT. TRISTAN ENGINEERING

PT. Tristan engineering is a company engaged in services and goods. This company provides services and procurement of goods or spare parts needed by other companies. The Xray machine moves 165 rpm for 24 hours non-stop in checking the goods that come in and out of the company. In this situation the damage can occur at any time and can cause uncertainty about the availability of the machines to support the checking process. The purpose of this research is to determine the application of the system and the benefits of the Reliability Centered Maintenance system on the application of maintenance of the xray machine conveyor motor. The research method used is the Reliability Centered Maintenance method, which is a method used to reduce downtime that occurs in PT. Tristan Engineering. The research results obtained at PT. Tristan Engineering include the absence of periodic maintenance, causing damage to the xray engine components. From the results of the improvement of the proposed conveyor motor maintenance application, the occurrence of downtime is caused by the identification of the failure to detect the severity value, occurrence, and detection of each component of the discussion and conclusion described using the FMEA method is 683 RPN, it must be done periodically machine maintenance. From the planning effort of Reliability Centered Maintenance accompanied by a comparative analysis it is found that the proposed improvements can reduce the average downtime by 39% on the problems of each component accompanied by MTBF 2.412 hour

Maintenance Preventive Scheduling of Critical Components in Offset Printing Machine (Case Study : PT. XYZ)

Maintenance activities are generally considered as supporting activities in the production process. However, this activity is very important because it contributes directly to the smooth running of the production process and productivity. PT. XYZ is a company engaged in mass media or newspapers since September 8, 2015. In the newspaper production process, PT. XYZ experienced delays in the production process due to damage to the component parts of the printing machine, in which the Offset printing machine is the core printing machine that is always used to print newspapers. Based on data on the frequency of damage during 2020 which was obtained from observations and interviews with operators, damage to machine components for 1 year on the offset printing machine counted 73 times that it was damaged. Thus making the machine stop operating from the effective working time of the machine, which is 264 days/year. This is due to the unavailability of a machine maintenance schedule because the company is still implementing a breakdown maintenance system. Thus the researcher aims to calculate the value of the identified critical components and calculate the effective time of machine operation for scheduling replacement of critical components of offset printing machines using the Reliability Centered Maintenance method. Based on the results of data processing using the Reliability Centered Maintenance method, the contactor component is determined as a critical component where the value of the Risk Priority Number is 72 with an average checking time of 11,250 minutes and component replacement time of 7 times/year. For this reason, it can be concluded that the contactor is a critical component with a damage value of 72 and the scheduling time for component replacement is 7 times in 1 year.

Decision-making regarding the best maintenance strategy for electrical equipment of buildings based on fuzzy analytic hierarchy process; case study: elevator

PurposeThe purpose of this paper is to propose the best method of maintenance for electrical equipment of a building and especially elevators in order to achieve various benefits.Design/methodology/approachLiterature review shows that there are various methods such as corrective maintenance, condition-based maintenance, time-based maintenance and reliability-centered maintenance (RCM) for the maintenance of electrical equipment of a building. Selecting the most appropriate maintenance method, especially in large buildings such as commercial ones, is a multiple-criteria decision-making problem. To solve this problem, the fuzzy analytic hierarchy process is used in the present study. It considers the uncertainties of the experts' judgments to provide an optimized maintenance method.FindingsTheoretically, the RCM method will take a lot of time and cost. But in prioritizing the methods, RCM gained more points with regard to safety criteria and value added. The main finding of this study suggests that RCM can be used in the case of elevators and would improve the safety and reliability of buildings.Originality/valueThe authors believe that this study will be valuable because one of the problems in building maintenance complexes is the lack of knowledge about the best method to prevent the risks of elevators. The proposed method has compared with other methods in various sub-criteria, and the results have been fully analyzed.

ANALISIS PENERAPAN PERAWATAN MOTOR KONVEYOR MESIN XRAY DENGAN MENGGUNAKAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) PADA PT. TRISTAN ENGINEERING

PT. Tristan engineering is a company engaged in services and goods. This company provides services and procurement of goods or spare parts needed by other companies. The X-ray machine moves 165 rpm for 24 hours non-stop in checking the goods that come in and out of the company. In this situation, the damage can occur at any time and can cause uncertainty about the availability of the machines to support the checking process. This research aims to determine the application of the system and the benefits of the Reliability Centered Maintenance system on the application of maintenance of the x-ray machine conveyor motor. The research method used is the Reliability Centered Maintenance method, which is used to reduce downtime that occurs in PT. Tristan Engineering. The research results were obtained at PT. Tristan Engineering includes the absence of periodic maintenance, causing damage to the x-ray engine components. From the results of the improvement of the proposed conveyor motor maintenance application, the occurrence of downtime is caused by the identification of the failure to detect the severity value, occurrence, and detection of each component of the discussion and conclusion described using the FMEA method is 683 RPN, it must be done machine maintenance periodically. From the planning effort of Reliability Centered Maintenance accompanied by a comparative analysis, the proposed improvements can reduce the average downtime by 39% on the problems of each component accompanied by MTBF 2.412 hours

Analisa Perbaikan Manajemen Perawatan Dengan Metode Reliability Centered Maintenance Bagian Cnc Wirecut di PT X

PT X is one of the manufacturing companies in Indonesia, which specializes in manufacturing molds and dies which offers products to the internal group and the domestic market. This study discusses the policy analysis of machine repair maintenance management using the RCM (Reliability Centered Maintenance) method approach at the PT X manufacturing company. Some of the problems that occur are sudden engine failure, which will cause over production. One machine that is considered critical is the CNC Wirecut K90 machine. With the application of using RCM it is expected to improve machine reliability through several systematic RCM implementations: system selection and information collection, defining system boundaries, system descriptions and function block diagrams, describing system functions and functional failures, compiling Failure Mode and Effect Analysis (FMEA), composing Logic Tree Analysis (LTA), selection of actions. The new policy set by the Realibility Centered Maintenance (RCM) method consists of 14 failure modes that are resolved by time-directed (CD) and 6 failure modes that are overcome by run to failure (RTF). In the FMEA analysis, there are 4 components that most often fail to function, namely the electrode pin, wire guide, filter and contact fit. The determination of this component is based on the RPN value and data in the field. In the RCM analysis, the electrode pin, wie guide and contact fit components are included in the run to failure (RTF) treatment policy category. Meanwhile, the filter component is in the category of condition direction (CD) maintenance policy with an average failure rate of 29,951 days.