Design Of Machine Operation And Maintenance System Based On The Reliability Engineering And Human Reliability Assessment (HRA) Approach At PT. Ima Montaz Sejahtera

Feb 27, 2025 by ADMIN 164 views

**Design of Machine Operation and Maintenance System at PT. Ima Montaz Sejahtera**

Introduction

In today's highly competitive industrial world, increased productivity is one of the key benchmarks of a company's success. PT. Ima Montaz Sejahtera, a leading manufacturer of packaged drinking water products, faces significant challenges in achieving this goal due to the availability of machines and human resources. Low productivity levels are often caused by the high rate of engine damage, particularly in the cup machine, which originates from the failure of engine components. This problem has a significant impact on the company's inability to achieve production targets set in the work plan and budget.

The use of maintenance systems that are still corrective and the lack of application of Standard Operational Procedures (SOP) is one of the causes of ineffective operation and machine maintenance. Research shows that the improvement of machine maintenance systems and routine scheduling for critical components is very necessary. With an in-depth analysis of machine maintenance and operation data, it can be identified that the implementation of clear SOPs, job descriptions, and workers' responsibilities greatly affects the increase in efficiency and effectiveness in the production process.

The Importance of Reliability Engineering and Human Reliability Assessment (HRA)

In this context, the Reliability Engineering and Human Reliability Assessment (HRA) approach is very relevant. Reliability engineering focuses on the development of a reliable system, by minimizing the risk of failure. By applying the principles of reliability, the company can increase the reliability of the machine and reduce the stopped time caused by damage. This approach is essential in ensuring that the machine operates efficiently and effectively, reducing the likelihood of downtime and increasing productivity.

Meanwhile, HRA stressed the importance of understanding the interaction between humans and machines. Human errors in the operation and maintenance of machines are often the main cause of production problems. Therefore, training and in-depth understanding of SOPs must be a priority. HRA allows companies to identify potential human errors and design systems that can minimize their impact. By understanding the human factor, companies can develop strategies to mitigate human errors and improve overall productivity.

Implementation Solution

To increase productivity, PT. Ima Montaz Sejahtera needs to take several strategic steps:

Revitalization of Maintenance Systems

Change the approach of the corrective maintenance system to the preventive and predictive maintenance system. This will reduce the possibility of engine damage and increase the availability of machines for production. Preventive maintenance involves regular maintenance tasks to prevent equipment failure, while predictive maintenance uses data and analytics to predict when equipment is likely to fail. By adopting this approach, PT. Ima Montaz Sejahtera can reduce downtime and increase productivity.

Effective SOP Application

Developing and applying clear SOPs for each operational process and machine maintenance is essential. This includes the development of guidelines that are easily understood by all workers. Standard Operating Procedures (SOPs) are a set of instructions that outline the steps to be taken in a specific situation. By developing clear SOPs, PT. Ima Montaz Sejahtera can ensure that all workers understand their roles and responsibilities, reducing the likelihood of human error.

Skilled Workers

Skilled workers will be better able to reduce human error. By providing training and development opportunities, PT. Ima Montaz Sejahtera can ensure that its workers have the necessary skills to operate and maintain the machines effectively.

Data Analysis and Performance Monitoring

Using technology to monitor machine performance and collect maintenance data is essential. This data analysis can provide valuable insights on damage trends and areas that need to be repaired. By analyzing data, PT. Ima Montaz Sejahtera can identify areas for improvement and develop strategies to mitigate human errors.

Conclusion

By applying the Reliability Engineering and HRA approach, PT. Ima Montaz Sejahtera can increase productivity, achieve better quality standards, and compete in the bottled drinking water industry market. The integration of these approaches can be the key to achieving optimal performance and reducing human errors. By revitalizing maintenance systems, applying effective SOPs, developing skilled workers, and analyzing data, PT. Ima Montaz Sejahtera can achieve its goals and become a leading manufacturer of packaged drinking water products.

Recommendations

Based on the findings of this study, the following recommendations are made:

PT. Ima Montaz Sejahtera should adopt a preventive and predictive maintenance system to reduce the possibility of engine damage and increase the availability of machines for production.
The company should develop and apply clear SOPs for each operational process and machine maintenance to ensure that all workers understand their roles and responsibilities.
PT. Ima Montaz Sejahtera should provide training and development opportunities to its workers to ensure that they have the necessary skills to operate and maintain the machines effectively.
The company should use technology to monitor machine performance and collect maintenance data to analyze damage trends and areas that need to be repaired.

By implementing these recommendations, PT. Ima Montaz Sejahtera can increase productivity, achieve better quality standards, and compete in the bottled drinking water industry market.

Q1: What is the main challenge faced by PT. Ima Montaz Sejahtera in achieving increased productivity?

A1: The main challenge faced by PT. Ima Montaz Sejahtera is the high rate of engine damage, particularly in the cup machine, which originates from the failure of engine components. This problem has a significant impact on the company's inability to achieve production targets set in the work plan and budget.

Q2: What is the importance of Reliability Engineering and Human Reliability Assessment (HRA) in machine operation and maintenance?

A2: Reliability Engineering and HRA are essential in ensuring that the machine operates efficiently and effectively, reducing the likelihood of downtime and increasing productivity. Reliability Engineering focuses on the development of a reliable system, by minimizing the risk of failure, while HRA stressed the importance of understanding the interaction between humans and machines.

Q3: What are the benefits of adopting a preventive and predictive maintenance system?

A3: Adopting a preventive and predictive maintenance system can reduce the possibility of engine damage and increase the availability of machines for production. This approach involves regular maintenance tasks to prevent equipment failure and uses data and analytics to predict when equipment is likely to fail.

Q4: How can Standard Operating Procedures (SOPs) help in reducing human error?

A4: Developing and applying clear SOPs for each operational process and machine maintenance can ensure that all workers understand their roles and responsibilities, reducing the likelihood of human error. SOPs are a set of instructions that outline the steps to be taken in a specific situation.

Q5: What is the role of skilled workers in reducing human error?

A5: Skilled workers will be better able to reduce human error. By providing training and development opportunities, PT. Ima Montaz Sejahtera can ensure that its workers have the necessary skills to operate and maintain the machines effectively.

Q6: How can data analysis and performance monitoring help in improving machine operation and maintenance?

A6: Using technology to monitor machine performance and collect maintenance data can provide valuable insights on damage trends and areas that need to be repaired. By analyzing data, PT. Ima Montaz Sejahtera can identify areas for improvement and develop strategies to mitigate human errors.

Q7: What are the recommendations for PT. Ima Montaz Sejahtera to improve machine operation and maintenance?

A7: Based on the findings of this study, the following recommendations are made:

Adopt a preventive and predictive maintenance system to reduce the possibility of engine damage and increase the availability of machines for production.
Develop and apply clear SOPs for each operational process and machine maintenance to ensure that all workers understand their roles and responsibilities.
Provide training and development opportunities to its workers to ensure that they have the necessary skills to operate and maintain the machines effectively.
Use technology to monitor machine performance and collect maintenance data to analyze damage trends and areas that need to be repaired.

Q8: What are the benefits of implementing the Reliability Engineering and HRA approach?

A8: By implementing the Reliability Engineering and HRA approach, PT. Ima Montaz Sejahtera can increase productivity, achieve better quality standards, and compete in the bottled drinking water industry market. The integration of these approaches can be the key to achieving optimal performance and reducing human errors.

Q9: How can PT. Ima Montaz Sejahtera ensure the success of the Reliability Engineering and HRA approach?

A9: PT. Ima Montaz Sejahtera can ensure the success of the Reliability Engineering and HRA approach by:

Providing training and development opportunities to its workers.
Developing and applying clear SOPs for each operational process and machine maintenance.
Adopting a preventive and predictive maintenance system.
Using technology to monitor machine performance and collect maintenance data.

Q10: What is the future outlook for PT. Ima Montaz Sejahtera after implementing the Reliability Engineering and HRA approach?

A10: By implementing the Reliability Engineering and HRA approach, PT. Ima Montaz Sejahtera can achieve significant improvements in productivity, quality, and competitiveness. The company can become a leading manufacturer of packaged drinking water products and achieve its goals in the bottled drinking water industry market.