TKP437-8-Pemeliharaan-dan-perbaikan-mesin.ppt

Teknik pemeliharaan mekanik mesin industri

1. PEMELIHARAAN &
PERBAIKAN MESIN

2. Kegagalan (Failure)
Failure – ketidakmampuan untuk melakukan kerja dengan
appropriate manner
Equipment / machine failure on production floor – worn
out bearing, pump, pressure leaks, broken shaft,
overheated machine etc.
Equipment failure in office – failure of power supply, air-
conditioned system, computer network, photocopy
machine
Vehicle failure – brake, transmission, engine, cooling
system

3. Konsekuensi Permasalahan Mesin
Masalah MesinDampak Langsung Biaya / Konsekuensi Akhir
MalfunctionDeteriorasi mesin Umur mesin singkat
  Ketidakefisienan mesinBiaya perbaikan tinggi
  Variabilitas outputScrap dan rework
Breakdown Bahaya keselamatanCedera
  Pekerja menganggurPersediaan
  Fasilitas menganggurBiaya perbaikan tinggi
   Penundaan jadwal

4. Pemeliharaan (Maintenance)
Semua aktivitas untuk memelihara fasilitas dan mesin
serta peralatan bekerja dengan baik sehingga sistem
dapat bekerja sebagaimana dimaksudkan
Meliputi: servicing, repair, modification, overhaul,
inspection and condition verification
Increase availability of a system
Keep system’s equipment in working order

5. Maintenance in Manufacturing Companies
Electronic
Automotive
Petrochemicals
Refinery
Furniture
Ceramics
Food and beverages

6. Tujuan Pemeliharaan
Upaya untuk memaksimalkan kinerja mesin dan
peralatan secara efisien dan teratur
Prevent breakdown or failures
Minimize production loss from failures
Increase reliability of the operating systems

7. Tujuan Dasar Pemeliharaan
(Principle Objectives in Maintenance)
Mencapai kualitas produk dan kepuasan pelanggan
melalui adjusted and serviced equipment
Memaksimalkan usia pemakaian mesin dan peralatan
Menjaga mesin dan peralatan aman dan mencegah
bahaya keselamatan
Meminimasi frekuensi dan lamanya interupsi atau
gangguan
Memaksimalkan kapasitas produksi – melalui utilisasi
tinggi fasilitas

8. Permasalahan dalam Pemeliharaan
Kurangnya perhatian manajemen pada pemeliharaan
Rendahnya partisipasi accounting dalam analisis dan
melaporkan berbagai jenis biaya
Kesulitan dalam menerapkan analisis kuantitatif
Kesulitan dalam mendapatkan estimasi waktu dan
biaya untuk pekerjaan pemeliharaan
Kesulitan dalam pengukuran kinerja

9. Maintenance Costs
Cost to replace or repair
Losses of output
Delayed shipment
Scrap and rework

10. Tipe Pemeliharaan
Reactive or Corrective Maintenance:
Breakdown maintenance
Reactive approach; dealing with breakdowns or problems
when they occur
Proactive Maintenance:
Preventive maintenance
Proactive approach; reducing breakdowns through a
program of lubrication, adjustment, cleaning, inspection, and
replacement of worn parts

11. Corrective or Breakdown Maintenance
Perbaikan dilakukan setelah mesin dan peralatan rusak
dan tidak dapat melakukan fungsinya secara normal
lagi
Dapat dibenarkan untuk pabrik kecil dimana:
 Waktu kerusakan bersifat tidak kritis dan biaya perbaikan
lebih rendah dari tipe pemeliharaan lainnya
Alasan keuangan untuk penjadwalan tidak ada

12. Kerugian Corrective Maintenance
Breakdown generally occurs inappropriate times leading to
poor and hurried maintenance
Excessive delay in production & reduces output
Faster plant deterioration
Increases chances of accidents and less safety for both
workers and machines
More spoilt materials
Direct loss of profit

13. Scheduled Maintenance
Scheduled maintenance is a stitch-in-time procedure and
incorporates
inspection
lubrication
repair and overhaul of equipment
If neglected can result in breakdown
 Generally followed for:
overhauling of machines
changing of heavy equipment oils
cleaning of water and other tanks etc.

14. Preventive Maintenance (PM)
Prinsip – “Prevention is better than cure”
Prosedur - Stitch-in-time
It
 locates weak spots of machinery and equipment
 provides them periodic/scheduled inspections and
minor repairs to reduce the danger of unanticipated
breakdowns

15. Candidates for Preventive Maintenance
Mean Time Between Failure (MTBF)Mean Time Between Failure (MTBF)
Frequency of FailureFrequency of Failure
Good candidates Good candidates
have more normal have more normal
distribution with distribution with
low variabilitylow variability

16. Keuntungan PM
Reduces break down and thereby down time
Less odd-time repair and reduces over time of crews
Greater safety of workers
Lower maintenance and repair costs
Less stand-by equipment and spare parts
Better product quality and fewer reworks and scraps
Increases plant life
Increases chances to get production incentive bonus

17. Kunci Keberhasilan Sistem PM
Scheduling – Should be automated to the maximum
extent possible
Execution – Should be done before the actual break
down occurs.

18. Execution
The Bath Tub Model – Three
stages of new parts
1.Infant mortality stage
2.A fairly long run stage
3.Wear out stage
Traditional View according to Bath
Tub Model – Replace components
just before they entered wear out
stage

19. Execution
Traditional view says –
Wear out stage = Increased rate of failure.

Point to Ponder –
Since, wear out stage represents increased rate of failure,
wouldn’t it be plausible to execute the PM program at this
stage?

20. Fokus PM
Cleaning Found through testing
Lubrication and inspection
And correcting deficiencies
Predetermined parts replacement should be minimal and done only where statistical evidence clearly indicates wear-
out characteristics

21. Predictive (Condition-based) Maintenance
In predictive maintenance, machinery conditions are
periodically monitored and this enables the
maintenance crews to take timely actions, such as
machine adjustment, repair or overhaul
It makes use of human sense and other sensitive
instruments, such as
audio gauge, vibration analyzer, amplitude meter, pressure,
temperature and resistance strain gauges etc.

22. Predictive Maintenance (Contd.)
Unusual sounds coming out of a rotating equipment
predicts a trouble
An excessively hot electric cable predicts a trouble
Simple hand touch can point out many unusual
equipment conditions and thus predicts a trouble

23. Maintenance Costs
Maintenance Maintenance
CommitmentCommitment
CostCost
Breakdown CostBreakdown Cost

24. Maintenance Costs
Maintenance Maintenance
CommitmentCommitment
CostCost
PM CostPM Cost
Breakdown CostBreakdown Cost

25. Maintenance Costs
Maintenance Maintenance
CommitmentCommitment
CostCost
PM CostPM Cost
Breakdown CostBreakdown Cost
Total Maintenance CostTotal Maintenance Cost

26. Maintenance Costs
Maintenance Maintenance
CommitmentCommitment
CostCost
PM CostPM Cost
Total Maintenance CostTotal Maintenance Cost
Breakdown CostBreakdown Cost
Optimal Optimal

27. Total Productive Maintenance (TPM)
Komitmen untuk melakukan pemeliharaan melebihi preventive and
predictive maintenance.
Semua pekerja terlibat dalam pemenuhan kepuasan pelanggan, dimana
pelanggan didefinisikan sebagai tahapan berikut dari sebuah proses
Suatu kerusakan mesin dilihat sebagai defect, dan TPM berkomitmen
untuk mencegah breakdown and malfunction
TPM merupakan aspek lanjutan dari continous improvement, yang
merupakan proses mengedukasi dan melibatkan pekerja, upgrading and
redesigning equipment, penerapan foolproofing devices, memonitor
kinerja mesin dan peralatan, dan mengeliminasi sumber-sumber
pemborosan mesin dan peralatan

28. Total Productive Maintenance (TPM)
TPM merupakan Japanese approach untuk
•Membuat budaya perusahaan untuk efisiensi
maksimum
•Upaya mencegah kerugian dengan biaya minimum
–Zero breakdowns and failures, Zero accident, and Zero
defects etc
•Esensi kerja tim (aktivitas kelompok kecil) berfokus
pada kondisi dan performansi fasilitas-fasilitas
untuk mencapai zero loss for improvement
•Keterlibatan semua SDM mulai dari top
management hingga operator

29. TPM
Production Operators
•Clean & Check
•Observe
•Categorize
Manufacturing Engineers
•Equipment Planning
•Equipment Studies
Production Planning &
Control
•Schedule P.M.
Quality Engineers
•Standards &
Calibrations
Active
Planned
Maintenance
Process

30. Asal TPM

31. A Socio-Technical System
Manufacturing (and many other) systems have both technical and
human/social aspects that are tightly bound and interconnected.
Moreover, it is the interconnections more than individual elements that
determine system performance.
The technical system includes machinery, processes, procedures and
a physical arrangement. We usually think of a factory in terms of its
technical system.
The social system includes people and their habitual attitudes, values,
behavioral styles and relationships. It includes the reward system. It is
the formal power structure as depicted on organization charts and the
informal power structure deriving from knowledge and personal
influence.
 

32. Hasil Penerapan TPM
3M reduced their maintenance cost by 60% within three years.
DuPont reduced off-quality by 69% and improved capacity by 29% in
three years.
Harley-Davidson estimates that the ROI from TPM has been ten-fold to
the cost of implementation.
Kodak reported a $5 million investment in TPM that resulted in a $16
million increase in profits.