PERAWATAN MESIN MS-4102(MAINTENANCE)
BAB I. PENDAHULUAN
PRODUCT LIFE CYCLE• Feasibility Study: apakah suatu mesin/pabrik layak
dibuat ditinjau dari segi ekonomi, lingkungan, teknologi.• Design: gambar desain dan spesifikasi teknik.• Build: tender, gambar konstruksi, konstruksi, as built
drawing • Commissioning: pengujian terhadap performance yang
dijanjikan, base line data.• Operation (untuk menghasilkan produk) & Maintenance
(supaya mesin tetap dapat dioperasikan dengan baik). • Decommissioning: untuk menentukan apakah mesin
sudah mencapai akhir umurnya.• Discard: mesin dibuang dan materialnya didaur ulang.
WHAT IS MAINTENANCE?Contoh:
Kita punya sebuah motor.
Apa yang kita lakukansupaya motor tetap dapatberfungsi dengan baik?
Apa tujuan kita memilikisepeda motor? Umumnyatujuan non komersial. Untung rugi bukanpertimbangan.
WHAT IS MAINTENANCE?• Yang kita lakukan (elemen aktifitas perawatan)
– Membersihkan (lap, cuci)– Memeriksa (dapat dilakukan sambil membersihkan)– Mengencangkan (mur/baut, jari2 yang kendor, rantai, memompa
ban, menyetel arah kaca spion, menyetel rem)– Melumasi (rantai, kabel rem, pedal rem)– Menyediakan suku cadang (bohlam, busi)– Perbaikan ringan (dilakukan sendiri)– Perbaikan berat (dilakukan oleh bengkel)
• Tujuan– Supaya performancenya tetap baik (performance mesin,
tampilan)– Aman dikendarai– Tidak mencemari lingkungan
WHAT IS MAINTENANCE?Kita punya armada motor (untukojek).
Tujuan komersial: untung rugimerupakan pertimbangan penting.
Motor harus dijaga supaya tetapproduktif dan tidak rewel.
Melibatkan banyak orang: perludigaji, perlu koordinasi.
Inventarisasi: merek motor, tahunpembuatan, jadwalpengoperasian, jadwal perawatan.
WHAT IS MAINTENANCE?
WHAT IS MAINTENANCE?• Untuk suatu pabrik apa yang dilakukan dan tujuannya
serupa dgn untuk motor.• Jumlah orang yang terlibat lebih banyak• Jumlah dana lebih banyak• Aspek komersial memerlukan pengorganisasian semua
kegiatan:– Strategi perawatan– Penugasan & koordinasi– Inventarisasi aset dan SDM– Penyediaan suku cadang– Pembelian barang dan jasa– Sistem informasi– Perencanaan perawatan/perbaikan– Penjadwalan perawatan/perbaikan
WHAT IS MAINTENANCE?
Pabrik dengan jumlah peralatan dan jenis sangat banyak.• Peralatan putar (rotating equipments)
– Pompa, kompresor, turbin, diesel• Peralatan statik (tidak berputar)
– Pressure vessels, reaction column, knocking drum, heat exchanger, tangki, piping
• Elektrik– Motor listrik, generator, transformer, distribution panels
• Instrumen dan sistem kendali– Pressure gauge, termometer, level meter, flow meter– PLC, DCS– Hidrolik, pneumatik
• Bangunan, prasarana (jalan, gedung, platform, air, bengkel, dlsb)
WHAT IS MAINTENANCE?• Asal kata : to maintain• Arti: (1) memelihara• Arti: (2) merawat• Arti: (3) menjaga• Apa yang di maintain?
– mesin/peralatan: supaya tidak rusak– performance (kualitas, kuantitas, efisiensi): supaya
memenuhi kriteria– aspek keselamatan: supaya tidak membahayakan
personil– aspek lingkungan: supaya tidak mencemari
lingkungan
WHAT IS MAINTENANCE?
Per
form
ance
Waktu
DenganPM
Performance Min
TanpaPM
WHAT IS MAINTENANCE?P
erfo
rman
ce
Waktu
CM CM
PM
Maintenance record
Performance min
WHAT IS MAINTENANCE?• Teknik (bayangkan anda hanya menghadapi 1 motor)
– Bagaimana melumasi– Bagaimana cara menyetel– Bagaimana cara membongkar & memasang– Bagaimana cara mendeteksi kerusakan
• Manajemen (bayangkan anda mempunyai 100 motor)– Bagaimana menyediakan “personil”, menentukan tugas dan
wewenangnya– Mendidik, melatih dan menyemangati personil– Merekam data dan informasi– Bagaimana menyediakan dan membeli suku cadang– Bagaimana membuat planning– Bagaimana menjadwal– Bagaimana menyediakan dana– Bagaimana mengorganisasikan (visi, misi)
WHAT IS MAINTENANCE?• Teknik
– Fokus ke mesin, lebih jelas (bukan berarti mudah)– Ada manual teknik dari pembuat mesin– Ada catatan sejarah perawatan mesin– Ada code dan standard (SNI, API, ASME, JIS, DIN dlsb)– Ada peraturan keselamatan kerja, peraturan lingkungan hidup,
OSHA (Occupational Safety and Hazard Association)• Manajemen
– Fokus ke manusia– Ada ilmunya tapi tidak “exact” seperti yang teknik– Melibatkan unsur “seni”– Dipengaruhi budaya setempat (etos kerja, disiplin, rasa memiliki)– Tergantung xxxx
WHAT IS MAINTENANCE?• Unplanned maintenance: kegiatan perawatan tidak terjadwal
karena keadaan darurat.• Planned maintenance: kegiatan perawatan terjadwal (biasanya
jangka panjang/tahunan). Seringkali mesin produksi tidak dapatdihentikan begitu saja untuk maintenance.
• Breakdown maintenance (RTF = Run To Failure): strategiperawatan dimana mesin dibiarkan saja beroperasi sampaikerusakan terjadi.
• Preventive maintenance: strategi perawatan (cleaning, inspection, small repair, lubrication) untuk mencegah konsekuensi kegagalanpada tingkat komponen maupun tingkat pabrik.
• Corrective maintenance: adalah strategi untuk memperbaikikomponen yang mengalami kegagalan.
• Running maintenance: kegiatan maintenance yang dapatdikerjakan ketika mesin sedang beroperasi
• Shutdown maintenance: kegiatan maintenance yang hanya dapatdikerjakan ketika mesin sedang tidak beroperasi
WHAT IS MAINTENANCE?• Emergency maintenance: kegiatan perawatan/
perbaikan untuk mengatasi kerusakan yang tidakterduga.
• Availability: ketersediaan/kesiapan mesin utkdioperasikan
• MTBF (mean time between failure): jangka waktuantara dua kerusakan berturut-turut.
• MTTR (mean time to repair): jangka waktu untukmenyelesaikan perbaikan.
• Down time: periode waktu dimana mesin tidak dapatdioperasikan
• Facility register (master equipment list): basis data peralatan, termasuk komponen dan perlengkapannya.
WHAT IS MAINTENANCE?• Maintenance management: pengelolaan kegiatan perawatan• Maintenance planning: perencanaan kegiatan perawatan selama 1
tahun.• Maintenance scheduling: penjadwalan kegiatan perawatan
selama 1 tahun.• Overhaul: membongkar mesin sebagian atau keseluruhan dan
memperbaikinya supaya diperoleh kondisi sesuai standar.• User: pengguna• Owner: pemilik• Vendor: penyedia alat/mesin• Efficiency: running hours / (running hours + down time)• Trip: mesin mati secara otomatis karena ada parameter operasi
(suhu, getaran dll) yang melebihi batas aman.• Shut in: mesin dimatikan secara sengaja.• Shut down: mesin mati dengan sendiri.
WHAT IS MAINTENANCE?
Maintenance
Planned maintenance Unplanned maintenance
Preventive maintenance
Corrective maintenance Emergency
maintenance
Overhaul
Minor Major
Shutdown maintenance
•Cleaning
•Inspection
•Small repair
Running maintenance
WHY DO MACHINES FAIL?• Wajar
– Aus (wear): scuffing, galling, fretting, abrasion – Lelah (fatigue)– Karat (corrosion)– Erosi (erosion)– Penuaan (aging)
• Prematur– Pelumasan tidak bagus (kualitas, kuantitas pelumas,
periode penggantian pelumas tidak benar)– Kotor/kontaminasi– Overheated– Misalignment (pada kopling, bearing, belt, rantai)
WHY DO MACHINES FAIL?OverheatedBrinelling karena overloaded
WHY DO MACHINES FAIL?
Fatigue damage
FAILURE PATTERN• Dahulu orang percaya bahwa semua kegagalan
komponen mengikuti “bathtub curve”• Ternyata bathtub curve tsb hanya mencakup 4% dari
populasi komponen (mis: bearings, connector, switches, IC, PCB, etc)
• Age related failure hanya 11%
Failu
re R
ate
Time
Useful life period
(wealth cycle)
Start up cycle
Break down cycle
Critical wear point
FAILURE PATTERNArti dari bathtub curve• Start up cycle: kerusakan terjadi karena ketidak
sempurnaan material, pengerjaan, pemasangan, pelatihan operator. Pada saat awal komponen mesinakan saling menyesuaikan karena berbagai ketidaksempurnaan pembuatan (permukaan masih kasar yang saling menghaluskan)
• Useful life: mesin berproduksi dengan baik karenakomponen2nya sudah saling menyesuaikan
• Break down cycle: komponen mengalami fatigue, keausan berlebih, erosi, abrasi dlsb.
Bath tube curve cocok untuk komponen mekanik.
FAILURE PATTERN
7%
14%
68%
2%
5%
4%
Age related failure (1, 2, 3)
Artinya: komponen akanrusak ketika sudah tua
Age unrelated failure (4, 5, 6)
Artinya: komponen bisagagal secara random, padasaat masih muda maupunsesudah tua
FAILURE PATTERN POPULATION PERCENTAGE
1
2
3
4
5
6
FAILURE PATTERN
1940 1950 1960 1970 1980 1990 2000
Kategori Mesin/Peralatan Produksi
• Ditinjau dari tingkat kerumitan, harga, peranan dan resiko dalam suatu matarantai produksi, mesin digolongkan atas. – Critical– Essential (Potentially critical)– General Purpose (Non critical)
• Kategori ini untuk menentukan strategiperawatan yang cocok.
Mesin “Critical”
• Kalau rusak dapat membahayakan• Kalau rusak proses produksi terganggu• Investasi mahal• Biaya perbaikannya mahal (misal: high
speed turbine)• Waktu untuk perbaikan lama
Mesin “General Purpose”
• Kalau rusak tidak membahayakan• Kalau rusak tidak mengganggu proses
produksi• Investasi tidak mahal• Biaya perbaikan tidak mahal• Mempunyai unit cadangan• Tidak mengakibatkan kerusakan sekunder
Mesin Essential (Potentially Critical)
• Di antara mesin critical dan general purpose.
BAB II PERKEMBANGAN
STRATEGI PERAWATAN
PERKEMBANGAN STRATEGI PERAWATAN
• Sebelum PD II rancangan mesin sederhana, kokoh, berat, “robust”
• Perawatan sederhana• Munculnya sistem produksi massal berarti
kerusakan mesin produksi dapat menimbulkankerugian besar
• Bersamaan dgn itu, rancangan mesinbertambah rumit, ringan, ramping
• Perlu strategi baru dalam perawatan
PERKEMBANGAN STRATEGI PERAWATAN
Generasi ketiga-Availability dan reliability lebih
baik-Keselamatan lebih baik-Kualitas produk lebih baik-Tidak mencemari lingkungan-Umur peralatan lebih panjang-Efektifitas biaya lebih baik
Generasi kedua-Availability lebih baik-Umur peralatan lebih
panjang-Efektifitas biaya lebih baik
Generasi pertama-Perbaiki kalau rusak
Tuntutan yang semakin meningkat thd maintenance
1940 1950 1960 1970 1980 1990 2000
PERKEMBANGAN STRATEGI PERAWATAN
Generasi ketiga-Pemantauan kondisi mesin-Design for reliability and
maintainability-Hazard studies-Komputer kecil, cepat-FMEA-Expert systems-Multi tasking and teamworks
Generasi kedua-Overhaul terjadwal-Sistem utk perencanaan dan
pengendalian kerja-Komputer besar dan lambat
Generasi pertama-Perbaiki kalau rusak
1940 1950 1960 1970 1980 1990 2000
PERKEMBANGAN FILOSOFI PERAWATAN
• Break down (run to failure) maintenance : mesindioperasikan tanpa perawatan sampai kerusakan terjadi. Kerusakan primer hampir selalu menimbulkan kerusakansekunder.
• Preventive maintenance (PM) atau time base maintenance: mesin di”maintain” secara terjadwalsetelah beroperasi dalam jangka waktu tertentu.
• Predictive (on condition based) maintenance (PdM): kondisi mesin dipantau secara menerus. Bila terdeteksiadanya ketidak normalan baru diambil tindakan.
• Proactive (prevention) maintenance: kerusakan yang terjadi dicari penyebabnya untuk mencegah kerusakanyang sama berulang.
PERKEMBANGAN FILOSOFI PERAWATAN
2 year leaseAutomobile tiresOil changeHead lightComponent you would maintain
Could be expensive
Costly if implemented incorrectly
Unnecessary replacement of parts. Poor utilization of labor.
High spare stock level.Emergency outages
Disadvantages (when implemented correctly)
Less maintenance required
Can spot potential failure
Can be planned for or scheduled
CheapAdvantages (when implemented correctly)
Redesign to eliminate root cause of failure
Maintain based upon known condition/standard
Conduct maintenance at regular intervals
Fix it when it breaks, Run to Failure
Definition
Proactive Maintenance
Predictive Maintenance
Preventive Maintenance
Reactive,Run To Failure
Strategy
RunRun--toto--Failure MaintenanceFailure Maintenance
•• RunRun--toto--failure maintenance is sometimes failure maintenance is sometimes called "crisis maintenance" for good called "crisis maintenance" for good reason. This has been the dominant form reason. This has been the dominant form of maintenance for a long time, and its of maintenance for a long time, and its costs are relatively high because of costs are relatively high because of unplanned downtime, damaged unplanned downtime, damaged machinery, and overtime expenditure. machinery, and overtime expenditure.
•• REACTIVEREACTIVE::–– Trouble / Breakdown / RTF / M&RTrouble / Breakdown / RTF / M&R
•• ““Fix it when it breaksFix it when it breaks”” –– ““Run to failureRun to failure””
•• PREVENTIVEPREVENTIVE (PM): (PM): Functional Checks of EquipmentFunctional Checks of Equipment–– For Rotating Equipment:For Rotating Equipment:
•• LubricationLubrication•• BeltsBelts•• FiltersFilters•• HousekeepingHousekeeping•• Visual ObservationsVisual Observations
–– Work Orders generated Facility Asset Management Work Orders generated Facility Asset Management Information SystemInformation System
Periodic Preventive MaintenancePeriodic Preventive Maintenance•• Periodic preventive maintenance, which is sometimes called Periodic preventive maintenance, which is sometimes called
"historical" maintenance. This is where the histories of each "historical" maintenance. This is where the histories of each machine type are analyzed and periodic overhauls are scheduled tmachine type are analyzed and periodic overhauls are scheduled to o occur before the statistically expected problems occur. It has loccur before the statistically expected problems occur. It has long ong been known that most groups of similar machines will exhibit faibeen known that most groups of similar machines will exhibit failure lure rates that are somewhat predictable if averaged over a long timerates that are somewhat predictable if averaged over a long time. . This gives rise to the soThis gives rise to the so--called "Bathtub Curve" which relates failure called "Bathtub Curve" which relates failure rate to operating time, as follows:rate to operating time, as follows:
PREVENTIVE MAINTENANCE (TIME BASED)
• Preventive maintenance adalah suatu tindakan untukmenjaga agar peralatan tetap dapat beroperasi dengancara inspeksi, deteksi dan pencegahan kerusakan.
• Semua kegiatan perawatan dijadwal berdasar waktu(mingguan, bulanan, triwulanan, 1000 jam, 3000 jam dlsb)
• Pelaksanaan mudah, tinggal mengikuti jadwal: pembersihan, pengecatan, pelumasan, pemeriksaan, perbaikan.(Rencana dan jadwal tahunan harusdisiapkan).
• Penganggaran mudah: anggaran umumnya dibuattahunan.
PREVENTIVE MAINTENANCE (TIME BASED)
• Murphy Law: Kerusakan biasanya terjadi pada waktuperalatan sangat dibutuhkan.
• Contoh: Pada saat banyak order, peralatan produksirusak. Perbaikan dapat memakan waktu beberapa jam atau beberapa hari.
• Hal yang tidak menguntungkan ini dapat dicegah denganPM.
• Alasan lain: keselamatan, penghematan biaya perbaikankarena kerusakan sekunder.
PREVENTIVE MAINTENANCE (TIME BASED)
Peralatan apa yang cocok untuk di PM?• Peralatan yang menyebabkan :
– “major shut down”, – penurunan kualitas produk, – kerusakan terhadap komponen terkait, – bahaya kepada karyawan
• Penerangan, lantai, plafon yang dapat mengganggukualitas produksi atau menimbulkan kondisi kerja yang buruk.
PREVENTIVE MAINTENANCE (TIME BASED)
Peralatan apa yang tidak perlu di PM? (cukup dg RTF)• Peralatan yang mempunyai cadangan• Peralatan yang harganya lebih rendah dari biaya PM• Peralatan yang umur harapannya cukup panjang tanpa
PM
Example• 3 pumps of exactly the same type and manufacturer, however, each
requires different maintenance strategy.– Pump A: Preventive maintenance (PM)– Pump B: Break down maintenance (RTF)– Pump C: Periodic test to eliminate hidden failure or PM
Pump A (continuous running)
Pump B (continuous running)
Pump C (standby, hidden failure)
100 l/min cooling water
100 l/min cooling water
Production Train 1
Loss USD 200,000./day when stop
Production Train 1Loss USD 200,000./day when stop
Example• 3 pumps of exactly the same type and manufacturer• Pump A: Predictive maintenance ???• Pump B: Break down maintenance???• Pump C: Periodic test???
Pump A (continuous running)
Pump B (continuous running)
Pump C (standby, hidden failure)
100 l/min nitric acid
100 l/min nitric acid
Production Train 1
Loss USD 200,000./day when stop
Production Train 1Loss USD 200,000./day when stop
PREVENTIVE MAINTENANCE (TIME BASED)
PM
cos
t
% maintenance delay
Lebih banyak uang untuk PM, terjadisedikit keterlambatan
Lebih sedikit uang untuk PM, terjadi banyak keterlambatan
PREVENTIVE MAINTENANCE (TIME BASED)
Cos
t
% maintenance delay
Production cost due to delay
Production cost as affected by maintenance cost
PM cost#1
#3
#2
PREVENTIVE MAINTENANCE (TIME BASED)
• #1: terlalu banyak PM, menghamburkan tenaga, sukucadang dan uang.
• #2: sangat kurang, akan terjadi banyak kerusakan• #3: sangat optimum, tapi jarang tercapai. Indikasinya
20% peralatan mengalami kerusakan sebelumdiperbaiki.
• Bila tidak terjadi kerusakan sebelum diperbaiki berartiPM terlalu banyak.
PREVENTIVE MAINTENANCE (TIME BASED)
• Rumus empirik untuk menentukan faktor PM (makintinggi nilainya PM makin perlu)
PM = D(A+B+C)/(EF)PM = inspection factorD = number of break down/yearA = cost of break down repairsB = cost of lost productionC = cost of repairing other equipment involved in the
breakdownE = cost of PM activity (average)F = number of PM cycle per year
PREVENTIVE MAINTENANCE (TIME BASED)
Do PM (Preventive Maintenance) if number of break down x Average cost per break down x 70% > cost of PM system
PREVENTIVE MAINTENANCE (TIME BASED)
Optimum Frequency/Interval for PM ditentukan berdasar:• Failure history• CM history• Manufacturer recommendations• Industry history• Regulatory requirements• Design and operation considerations• Other tasks scheduled on the same component• Planned outages• Ability to gain access to the component• Operator capability• PdM monitoring activity• Environment
PM Tasks
Ask operator how machine is operatingInterview operatorHistory analysis of a type of machineAnalysisRemove and replace pumpScheduled replacementAdd oilLubricateRead temperature, pressure, vibrationTake readingAdjust tightening boltAdjustingWarming up machine/prepare for operationOperatingTighten anchor boltsTighteningRemove debris from machinesCleaningLook for leak in hydraulic systemInspectionExampleType of Task
PREVENTIVE MAINTENANCE (TIME BASED)
Inspection• Memastikan performansi peralatan sesuai perancangan• Mengevaluasi semua komponen terhadap masalah yang
potensial menimbulkan kerusakan• Mengidentifikasi komponen yang dapat menyebabkan
kerusakan dan mengestimasi waktu sampai kerusakanterjadi. Contoh: dinding pressure vessel mengalamipenipisan selama dioperasikan.
PREVENTIVE MAINTENANCE (TIME BASED)
Inspeksi dilakukan• Karena tuntutan peraturan: Pressure vessel harus
diinspeksi secara berkala sesuai dengan peraturanpemerintah tentang keselamatan kerja.
• Karena mesin tidak dilengkapi dengan cadangan danberesiko terhadap keberlangsungan proses produksi.
• Pada peralatan yang sedang rusak
CORRECTIVE MAINTENANCE (PERBAIKAN) SEBAGAI RESPONS TERHADAP INSPEKSI DALAM PM
Biaya perbaikan
Equ
ipm
ent a
vaila
bilit
y
PREDICTIVE MAINTENANCE (PdM)
Preventive Maintenance
Time Based Maintenance
Predictive Maintenance,
Condition Based Maintenance
Predictive MaintenancePredictive Maintenance•• Predictive maintenance allows management to control Predictive maintenance allows management to control
the machinery and maintenance programs rather than the machinery and maintenance programs rather than vice versa. In a plant using predictive maintenance, the vice versa. In a plant using predictive maintenance, the overall machinery condition at any time is known, and overall machinery condition at any time is known, and much more accurate planning is possible.much more accurate planning is possible.
•• Benefits of Predictive MaintenanceBenefits of Predictive Maintenance–– The major benefit of predictive maintenance of The major benefit of predictive maintenance of
mechanical equipment is increased readiness due to mechanical equipment is increased readiness due to greater reliability of the equipment. The trending over greater reliability of the equipment. The trending over time of developing faults in machines can be carefully time of developing faults in machines can be carefully done so as to plan maintenance operations to done so as to plan maintenance operations to coincide with scheduled shutdownscoincide with scheduled shutdowns..
SAAT PERAWATAN YANG TEPAT
Predictive Maintenance (PdM). Perbaikan tepat pada waktunya
Time based preventive maintenance (PM)
Mesin terlambatdiperbaiki
Perbaikan dilakukanterlalu awal
Predictive Maintenance TechnologiesPredictive Maintenance Technologies
•• Infrared Infrared ThermographyThermography•• Lubrication analysisLubrication analysis•• Vibration AnalysisVibration Analysis
Energy and Power ConsiderationsEnergy and Power Considerations
•• Energy is required to produce vibration and in the case Energy is required to produce vibration and in the case of machine vibration, this energy comes from the source of machine vibration, this energy comes from the source of power to the machine. This energy source can be the of power to the machine. This energy source can be the AC power line, an internal combustion engine, or steam AC power line, an internal combustion engine, or steam driving a turbine, etc. Energy is defined as force driving a turbine, etc. Energy is defined as force multiplied by the distance over which the force acts, and multiplied by the distance over which the force acts, and the SI unit of energy is the Joule. One Joule of energy is the SI unit of energy is the Joule. One Joule of energy is equivalent to a force of one Newton acting over a equivalent to a force of one Newton acting over a distance of one meter. The physical concept of work is distance of one meter. The physical concept of work is similar to that of energy, and the units used to measure similar to that of energy, and the units used to measure work are the same as those for measuring energy.work are the same as those for measuring energy.
Energy and Power ConsiderationsEnergy and Power Considerations•• The actual amount of energy present in the machine vibration itsThe actual amount of energy present in the machine vibration itself elf
is usually not very great compared to the energy required to opeis usually not very great compared to the energy required to operate rate the machine for its intended task.the machine for its intended task.
•• Power is defined as the rate of doing work, or the rate of energPower is defined as the rate of doing work, or the rate of energy y transfer, and according to the SI, it is measured in Joules per transfer, and according to the SI, it is measured in Joules per second, or Watts. One horsepower is equivalent to 746 watts. Powsecond, or Watts. One horsepower is equivalent to 746 watts. Power er is proportional to the square of the vibration amplitude, just ais proportional to the square of the vibration amplitude, just as s electrical power is proportional to the voltage squared or the celectrical power is proportional to the voltage squared or the current urrent squared.squared.
•• According to the law of conservation of energy, energy cannot beAccording to the law of conservation of energy, energy cannot becreated or destroyed, but it can be transformed into different fcreated or destroyed, but it can be transformed into different forms. orms. The vibratory energy in a mechanical system is ultimately dissipThe vibratory energy in a mechanical system is ultimately dissipated ated in the form of heat.in the form of heat.
PROACTIVE MAINTENANCE (PREVENTION MAINTENANCE)
• Kerusakan premature (belum saatnya) dapatterjadi atas peralatan
• Mencegah perbaikan berulang atas kerusakanpremature
• Kerusakan jenis tersebut harus dicaripenyebabnya dengan Root Cause Failure Analysis (RCFA)
• Improvement/redesign komponen dilakukanberdasar hasil RCFA
Proactive Maintenance Proactive Maintenance TechnologiesTechnologies
•• Dynamic BalancingDynamic Balancing•• Precision Shaft AlignmentPrecision Shaft Alignment•• Ultrasonic Testing / Air & SteamUltrasonic Testing / Air & Steam•• Belt / Pulley AlignmentBelt / Pulley Alignment•• Acceptance TestingAcceptance Testing•• Water / Air Flow balancing & MeasuringWater / Air Flow balancing & Measuring•• MeteringMetering
ProPro--active Maintenanceactive Maintenance
•• ProPro--active maintenance, which uses a variety of active maintenance, which uses a variety of technologies to extend the operating lives of technologies to extend the operating lives of machines and to virtually eliminate reactive machines and to virtually eliminate reactive maintenance. The major part of a promaintenance. The major part of a pro--active active program is root cause failure analysis (RCA), program is root cause failure analysis (RCA), which is the determination of the mechanisms which is the determination of the mechanisms and causes of machine faults. The fundamental and causes of machine faults. The fundamental causes of machine failures can thus be causes of machine failures can thus be corrected, and the failure mechanisms can be corrected, and the failure mechanisms can be gradually engineered out of each machinery gradually engineered out of each machinery installation.installation.
Maintenance Strategy Comparation
Heart attack or strokeLarge maintenance budget
Break down, Run To Failure, Reactive
By-pass or transplant surgery
Periodic components replacement
Preventive
Detection of heart disease by ECG or ultrasonic
Monitoring of vibration, temperature, alignment, pressure, wear debris
Predictive
Cholesterol and blood pressure monitoring, followed by diet control
Monitoring and correction of “failing root causes”
Proactive
Human Health ParallelTechnique NeededMaintenance Strategy
RCM (Reliability Centered Maintenance)
RCM (Reliability Centered Maintenance)
Reactive, RTF
PM, Time Based
PdM, Condition Based, Predictive
Proactive
•Small items
•Non critical
•Inconsequential
•Unlikely to fail
•Redundant
•Subject to wear out
•Consumable replacement
•Failure pattern known
•Random failure patterns
•Not subject to wear
•PM Induced failures
•Age exploration
•RCFA
•FMEA
•Acceptance testing
RCFA = Root Cause Failure Analysis
FMEA = Failure Mode and Effect Analysis
RCM (Reliability Centered Maintenance)
RULES FOR BREAKDOWN MAINTENANCE
• If equipment is redundant• Low cost spares available• Interruptible process, stock pile• Safe failure modes• Long MTTF/MTBF• Low cost secondary damage• Quick repair/replacement (low cost of interuption
of production)
RULES FOR PREVENTIVE MAINTENANCE
• Statistical failure rate available• Narrow failure distribution (predictable MTBF)• Maintenance restore full integrity• Single failure mode (known)• Low cost of regular overhaul/replacement• Unexpected interruption to production is
expensive (scheduled interruption is not so bad)• Low cost spares available• Reduced number of breakdown is required• Costly secondary damage
RULES FOR PREDICTIVE MAINTENANCE
• Expensive/critical machinery• Long lead time for replacement (no spares)• Uninterruptible process (both regular and unexpected)-
costly• Large/complex machinery• Overhaul expensive (need highly trained people)• Reduced number of highly skilled maintenance people• Cost of monitoring program is acceptable• Safety is priority (failure dangerous)• Remote/mobile equipment• Failure is not indicated by operation degeneration• Costly secondary damage
ALIRAN INFORMASI
Dari mana pekerjaan perawatan bermula?• Internal (dari dalam department of
maintenance): tugas preventive maintenance dan corrective maintenance
• Eksternal (dari luar departemen): permintaan dari manajer produksi, rehabilitasi
Komponen Penting dalamPerawatan
Gunung Es Perawatan
Organisasi Perawatan