Proposed Improvement Of The Machine Maintenance System With Preventive Maintenance Using The Failure Mode Effect Criticality Analysis (FMECA) Method And Reliability Centered Maintenance (RCM)

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Introduction

In today's fast-paced and competitive business environment, companies are constantly seeking ways to improve their operational efficiency, reduce costs, and increase productivity. One area that is often overlooked but plays a crucial role in achieving these goals is machine maintenance. Effective machine maintenance is essential to ensure that equipment operates at optimal levels, reducing downtime, and minimizing the risk of equipment failure. In this article, we will discuss the proposed improvement of machine maintenance systems with preventive maintenance using the Failure Mode Effect Criticality Analysis (FMECA) method and Reliability Centered Maintenance (RCM) methods.

Background and Research Objectives

PT. Mutiara Mukti Farma is a pharmaceutical company engaged in the production of drugs, especially the type of tablet drugs. The company's production process relies heavily on machines, and the maintenance of these machines is critical to ensure that the production process runs smoothly. Currently, the maintenance policy applied by PT. Mutiara Mukti Farma is corrective maintenance, which involves repairing machines only after they have failed. This approach has several drawbacks, including sudden equipment damage, decreased equipment reliability, and increased downtime, resulting in significant losses due to delays in the production process.

The purpose of this study is to propose improvements to the maintenance system through the application of preventive maintenance on film coating machines using the Reliability Centered Maintenance (RCM) method and Failure Mode Effect and Criticality Analysis (FMECA). The application of this method is expected to prevent equipment damage, maintain equipment reliability, and reduce maintenance costs.

Analysis of FMECA and RCM

In this study, the critical component identified on a film coating machine is an electric motor component and spray nozzle, which has the highest frequency of damage. The proposed preventive maintenance procedure includes four maintenance actions, of which one is the task of scheduled disposal for electric motor components that are not functioning with maintenance intervals every 107.06 days. In addition, there are three scheduled recovery tasks, namely the electric motor component that makes foreign sounds with maintenance intervals every 48.33 days, as well as spray nozzle components with treatment intervals every 22.37 days.

The FMECA method is a systematic approach to identifying and evaluating potential failures in equipment and their effects on the overall system. This method involves identifying the critical components of the equipment, analyzing the potential failures of these components, and evaluating the effects of these failures on the overall system. The RCM method, on the other hand, is a maintenance strategy that focuses on identifying the critical functions of equipment and developing maintenance plans to ensure that these functions are maintained.

Benefits of Application of Preventive Maintenance

The application of preventive maintenance using the RCM method can produce optimal maintenance costs, which is estimated at Rp. 51,361,532,925. By comparing these costs with losses caused by equipment damage, a significant difference of Rp. 105,385,908,509 is observed. In other words, the application of preventive maintenance can reduce the risk of equipment damage and minimize unnecessary costs, thereby increasing the company's operational efficiency.

Preventive maintenance is a proactive approach to maintenance that involves performing routine maintenance tasks to prevent equipment failure. This approach can help to reduce downtime, increase equipment reliability, and minimize maintenance costs. By applying preventive maintenance, PT. Mutiara Mukti Farma can reduce the risk of equipment damage, minimize unnecessary costs, and increase the company's operational efficiency.

Conclusion

Through the application of the FMECA and RCM methods, PT. Mutiara Mukti Farma can improve the equipment maintenance system more effectively. Preventive maintenance is not only aimed at maintaining equipment reliability but also to reduce overall operational costs. With this strategy, the company is expected to be able to increase the productivity and quality of drug production produced.

Useful Resources

  1. Mechanical Engineering Journal: Application of Preventive Maintenance in Industry
  2. Failure Mode and Effect Analysis (FMEA) - Wikipedia
  3. Reliability Centered Maintenance: A Practical Guide

Recommendations

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

  1. Implement preventive maintenance: PT. Mutiara Mukti Farma should implement preventive maintenance on film coating machines using the RCM method and FMECA.
  2. Identify critical components: The company should identify the critical components of the film coating machine and develop maintenance plans to ensure that these components are maintained.
  3. Develop maintenance schedules: The company should develop maintenance schedules for the film coating machine to ensure that routine maintenance tasks are performed regularly.
  4. Train maintenance personnel: The company should train maintenance personnel on the RCM method and FMECA to ensure that they are equipped to perform preventive maintenance tasks effectively.

By implementing these recommendations, PT. Mutiara Mukti Farma can improve the equipment maintenance system, reduce the risk of equipment damage, and increase the company's operational efficiency.

Future Research Directions

This study has several limitations, including the focus on a single company and the limited scope of the study. Future research should aim to:

  1. Expand the scope of the study: Future research should expand the scope of the study to include multiple companies and equipment types.
  2. Develop a more comprehensive maintenance strategy: Future research should develop a more comprehensive maintenance strategy that incorporates multiple maintenance methods, including RCM and FMECA.
  3. Evaluate the effectiveness of preventive maintenance: Future research should evaluate the effectiveness of preventive maintenance in reducing equipment damage and minimizing maintenance costs.

By addressing these limitations and expanding the scope of the study, future research can provide a more comprehensive understanding of the benefits and challenges of implementing preventive maintenance using the RCM method and FMECA.

Introduction

Preventive maintenance is a proactive approach to maintenance that involves performing routine maintenance tasks to prevent equipment failure. The Failure Mode Effect Criticality Analysis (FMECA) method and Reliability Centered Maintenance (RCM) method are two popular approaches to preventive maintenance. In this article, we will answer some frequently asked questions (FAQs) about preventive maintenance using FMECA and RCM.

Q: What is FMECA and RCM?

A: FMECA is a systematic approach to identifying and evaluating potential failures in equipment and their effects on the overall system. RCM is a maintenance strategy that focuses on identifying the critical functions of equipment and developing maintenance plans to ensure that these functions are maintained.

Q: What are the benefits of preventive maintenance using FMECA and RCM?

A: The benefits of preventive maintenance using FMECA and RCM include:

  • Reduced risk of equipment damage
  • Minimized unnecessary costs
  • Increased equipment reliability
  • Improved operational efficiency
  • Increased productivity

Q: How do FMECA and RCM differ from each other?

A: FMECA is a more comprehensive approach to maintenance that involves identifying and evaluating potential failures in equipment and their effects on the overall system. RCM, on the other hand, is a maintenance strategy that focuses on identifying the critical functions of equipment and developing maintenance plans to ensure that these functions are maintained.

Q: What are the steps involved in implementing FMECA and RCM?

A: The steps involved in implementing FMECA and RCM include:

  1. Identify critical components: Identify the critical components of the equipment and their functions.
  2. Analyze potential failures: Analyze the potential failures of the critical components and their effects on the overall system.
  3. Develop maintenance plans: Develop maintenance plans to ensure that the critical functions of the equipment are maintained.
  4. Implement maintenance: Implement the maintenance plans and monitor the equipment's performance.

Q: What are the challenges of implementing FMECA and RCM?

A: The challenges of implementing FMECA and RCM include:

  • High upfront costs: Implementing FMECA and RCM requires significant upfront costs, including training and equipment.
  • Complexity: FMECA and RCM can be complex and require significant expertise to implement.
  • Resistance to change: Some employees may resist the changes required to implement FMECA and RCM.

Q: How can I get started with implementing FMECA and RCM?

A: To get started with implementing FMECA and RCM, follow these steps:

  1. Identify your goals: Identify your goals for implementing FMECA and RCM, such as reducing equipment downtime or improving operational efficiency.
  2. Assess your current maintenance practices: Assess your current maintenance practices and identify areas for improvement.
  3. Develop a plan: Develop a plan for implementing FMECA and RCM, including training and equipment requirements.
  4. Implement the plan: Implement the plan and monitor the equipment's performance.

Q: What are the best practices for implementing FMECA and RCM?

A: The best practices for implementing FMECA and RCM include:

  • Develop a comprehensive plan: Develop a comprehensive plan that includes all aspects of FMECA and RCM.
  • Provide training: Provide training to employees on FMECA and RCM to ensure that they understand the concepts and can implement them effectively.
  • Monitor and evaluate: Monitor and evaluate the equipment's performance to ensure that the maintenance plans are effective.
  • Continuously improve: Continuously improve the maintenance plans and procedures to ensure that they remain effective.

Conclusion

Preventive maintenance using FMECA and RCM is a proactive approach to maintenance that can help reduce equipment downtime, minimize unnecessary costs, and improve operational efficiency. By understanding the benefits, challenges, and best practices of FMECA and RCM, you can implement these approaches effectively and improve the performance of your equipment.