Machine Maintenance Proposed Based On Spare Parts Reliability As A Solution To Reduce Treatment Costs At PT. New Hadi

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Introduction

PT. Hadi Baru is a company that operates in the crumb rubber manufacturing industry, where effective machine maintenance is crucial to keep production machines functioning optimally. Unfortunately, this company has prioritized corrective maintenance without considering the reliability of engine components, resulting in unexpected damage to engine components that often interferes with the production process. This study aims to propose a machine maintenance approach based on spare parts reliability as a solution to reduce maintenance costs at PT. New Hadi.

Background of the Study

PT. Hadi Baru is a company that operates in the crumb rubber manufacturing industry, where the production process involves the use of various machines, including the slab cutter engine. The slab cutter engine is a critical component of the production process, and its maintenance is essential to ensure the smooth operation of the production process. However, the company has been using a corrective maintenance approach, which involves repairing or replacing machine components only when they fail. This approach can lead to unexpected damage to engine components, resulting in production downtime and increased maintenance costs.

Methodology

To conduct this study, the data needed includes information about the engine components that are damaged, the frequency of damage, the time of replacement of components, the purchase price of each component, and labor costs. The focus of this study is fixed on the three critical components of the slab cutter engine, namely Blade Cutter, Clutch Disc, and TG Chain. By determining the function of the probability density, reliability, average time until fail (MTTF), failure costs, as well as preventive maintenance costs, then it can be determined the time interval of the replacement of each critical component by considering the lowest maintenance costs.

Data Analysis

The data analysis was conducted using the following steps:

  1. Data Collection: The data needed for this study was collected from various sources, including the company's maintenance records, production reports, and supplier information.
  2. Data Processing: The collected data was processed and analyzed using statistical software to determine the probability density, reliability, MTTF, failure costs, and preventive maintenance costs for each critical component.
  3. Results: The results of the study are presented in the following table:
Component Time Interval of Replacement (days) Reliability
Blade Cutter 11 0.90097
Clutch Disc 36 0.68850
TG Chain 37 0.76905

Discussion

The results of the study show that the time interval of replacement for each critical component is as follows:

  • Blade Cutter: The time interval of replacement is 11 days with a reliability of 0.90097.
  • Clutch Disc: The time interval of replacement is 36 days with a reliability of 0.68850.
  • TG Chain: The time interval of replacement is 37 days with a reliability of 0.76905.

The analysis shows that by applying the preventive maintenance approach, the replacement costs for the three critical components reached Rp 3,865,506. Meanwhile, if maintenance is carried out correctively, the costs to be incurred can reach Rp 5,314,127. This shows that the application of preventive maintenance can reduce maintenance costs by 27.25%.

Conclusion

The proposed maintenance of this machine not only provides a financial solution but also emphasizes the importance of systematic and data-based maintenance to ensure the survival of the engine operations in the long run. PT. Hadi only needs to consider these steps to be able to compete effectively in the increasingly competitive crumb rubber industry.

Recommendations

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

  1. Implement Preventive Maintenance: PT. Hadi should implement a preventive maintenance approach to reduce maintenance costs and ensure the smooth operation of the production process.
  2. Conduct Regular Maintenance: Regular maintenance should be conducted to ensure that machine components are functioning optimally and to prevent unexpected damage.
  3. Use Reliability Data: Reliability data should be used to determine the time interval of replacement for each critical component to ensure that maintenance is carried out at the optimal time.
  4. Train Maintenance Personnel: Maintenance personnel should be trained to ensure that they have the necessary skills and knowledge to carry out maintenance tasks effectively.

Limitations of the Study

This study has several limitations, including:

  1. Limited Data: The data used in this study was limited to the company's maintenance records and production reports.
  2. Small Sample Size: The sample size of this study was small, which may not be representative of the entire population.
  3. Assumptions: The study made several assumptions, including the assumption that the maintenance costs are directly proportional to the time interval of replacement.

Future Research Directions

Future research should focus on the following areas:

  1. Development of a Maintenance Model: A maintenance model should be developed to predict the time interval of replacement for each critical component based on reliability data.
  2. Implementation of a Maintenance System: A maintenance system should be implemented to ensure that maintenance is carried out regularly and effectively.
  3. Training of Maintenance Personnel: Maintenance personnel should be trained to ensure that they have the necessary skills and knowledge to carry out maintenance tasks effectively.

Conclusion

In conclusion, this study proposes a machine maintenance approach based on spare parts reliability as a solution to reduce maintenance costs at PT. New Hadi. The results of the study show that the application of preventive maintenance can reduce maintenance costs by 27.25%. The proposed maintenance approach not only provides a financial solution but also emphasizes the importance of systematic and data-based maintenance to ensure the survival of the engine operations in the long run.

Q: What is the main objective of this study?

A: The main objective of this study is to propose a machine maintenance approach based on spare parts reliability as a solution to reduce maintenance costs at PT. New Hadi.

Q: What are the critical components of the slab cutter engine that were studied in this research?

A: The three critical components of the slab cutter engine that were studied in this research are Blade Cutter, Clutch Disc, and TG Chain.

Q: What is the time interval of replacement for each critical component based on the results of this study?

A: The time interval of replacement for each critical component based on the results of this study is as follows:

  • Blade Cutter: 11 days
  • Clutch Disc: 36 days
  • TG Chain: 37 days

Q: What is the reliability of each critical component based on the results of this study?

A: The reliability of each critical component based on the results of this study is as follows:

  • Blade Cutter: 0.90097
  • Clutch Disc: 0.68850
  • TG Chain: 0.76905

Q: What are the benefits of implementing a preventive maintenance approach based on spare parts reliability?

A: The benefits of implementing a preventive maintenance approach based on spare parts reliability include:

  • Reduced maintenance costs
  • Improved machine reliability
  • Increased production efficiency
  • Reduced downtime

Q: What are the limitations of this study?

A: The limitations of this study include:

  • Limited data
  • Small sample size
  • Assumptions made in the study

Q: What are the recommendations for implementing a preventive maintenance approach based on spare parts reliability?

A: The recommendations for implementing a preventive maintenance approach based on spare parts reliability include:

  • Implementing a preventive maintenance approach
  • Conducting regular maintenance
  • Using reliability data to determine the time interval of replacement for each critical component
  • Training maintenance personnel

Q: What are the future research directions for this study?

A: The future research directions for this study include:

  • Developing a maintenance model to predict the time interval of replacement for each critical component based on reliability data
  • Implementing a maintenance system to ensure that maintenance is carried out regularly and effectively
  • Training maintenance personnel to ensure that they have the necessary skills and knowledge to carry out maintenance tasks effectively

Q: What are the implications of this study for PT. New Hadi?

A: The implications of this study for PT. New Hadi are:

  • Reduced maintenance costs
  • Improved machine reliability
  • Increased production efficiency
  • Reduced downtime

Q: What are the implications of this study for the crumb rubber industry?

A: The implications of this study for the crumb rubber industry are:

  • Improved machine reliability
  • Increased production efficiency
  • Reduced downtime
  • Improved competitiveness in the market

Q: What are the implications of this study for maintenance personnel?

A: The implications of this study for maintenance personnel are:

  • Improved skills and knowledge in maintenance tasks
  • Increased efficiency in maintenance tasks
  • Improved reliability of machines
  • Reduced downtime

Q: What are the implications of this study for the company's bottom line?

A: The implications of this study for the company's bottom line are:

  • Reduced maintenance costs
  • Improved machine reliability
  • Increased production efficiency
  • Reduced downtime
  • Improved competitiveness in the market

Q: What are the implications of this study for the company's reputation?

A: The implications of this study for the company's reputation are:

  • Improved reliability of machines
  • Increased production efficiency
  • Reduced downtime
  • Improved competitiveness in the market
  • Improved reputation for quality and reliability.