Analysis of Maintenance Management at PT.XYZ Power Plant (With MTTR, MTTF, and Availability Factors) and Development of Performance Improvement Program

Dida Nurdiansyah; Agustinus Hariadi D.P

doi:10.55927/fjmr.v3i9.11137

Authors

Dida Nurdiansyah Universitas Mercu Buana
Agustinus Hariadi D.P Mercubuana University

DOI:

https://doi.org/10.55927/fjmr.v3i9.11137

Keywords:

MTTF, MTTR, Availibility, Pareto Diagram, Preventive Maintenance, Autonomous Maintenance

Abstract

Damage data for machinery at PT. XYZ power plant between October-December 2023 shows that the pump is the component with the highest number of failures, recording 28 incidents (33.7% of the total 83 failures), followed by the condenser with 27 incidents (32.5%). The combined failures of these two components account for 66.3% of the total failures, indicating a need for focused improvements on the pump and condenser. The MTTR analysis for the pump shows a high average repair time: 7.7 hours in October, 7 hours in November, and 7.7 hours in December, with low availability rates (89.64%-89.69%). The MTTF for the pump varies from 65.2 to 75.4 hours, indicating the need for improved preventive maintenance strategies. It is recommended that maintenance be carried out every 2-3 days or at least once a week. The condenser has an MTTR ranging from 6.7 to 7.7 hours and low availability (88.89%-89.95%), with MTTF varying from 66.7 to 92.7 hours. The high MTTR and low availability of these two components highlight the need for improvements in maintenance management to enhance performance.

Downloads

Download data is not yet available.

References

Agus Endrawan, Aidil Ikhsan, (2021), Penentuan Interval Waktu Preventive Maintenance Mesin Vibro Jumbo Dengan Menggunakan Metode Reliability Centered Maintenance (RCM), Universitas Bung Hatta.

Agustinus Hariadi DP, Increasing Utilization of Production Machinery Through Line Balancing Approach (Case Study On Pharmaceutical Industry), Dinasti International Journal of Education Management And Social Science, Volume 2, Pages 1068-1082.

Anas Sani Maihulla, (2023), Weibull Comparison Based On Reliability, Availability, Maintainability, And Dependability (Ramd) Analysis, Journal RT&A, No 1 (72) Volume 18.

Andrzej Zyluk, Mariusz Zieja, Norbert Grzesik, Justyna Tomaszewska, Grzegorz Kozlowski and Michal Jasztal, (2023) Implementation of the Mean Time to Failure Indicator in the Control of the Logistical Support of the Operation Process, Journal Applied Science MDPI, Volume 13, Page 4608.

Bozena Zwoli ´nska and Jakub Wiercioch, (2022), Selection of Maintenance Strategies for Machines in a Series-Parallel System, Journal Sustainability MDPI, Volume 14, Page 11953.

Budi Setiyana, M Anas Juliansyah, Muchammad (2022), Maintenance Analysis of Aida 800 Machine using a Total Productive Maintenance Method through an Overall Equipment Efficiency (OEE) Approach, International Research Journal of Innovations in Engineering and Technology (IRJIET), Volume 6, Issue 9, pp 88-94.

David Mendes, Pedro D. Gaspar, Fernando Charrua-Santos and Helena Navas, (2023), Integrating TPM and Industry 4.0 to Increase the Availability of Industrial Assets: A Case Study on a Conveyor Belt, Journal Processes MDPI, Volume 11, Page 1956.

Dimitris Mourtzis, Sofia Tsoubou and John Angelopoulos, (2023), Robotic Cell Reliability Optimization Based on Digital Twin and Predictive Maintenance, Journal Electronic MDPI, Volume 12, Page 1999.

Dwi Prasetya, Ika Widya Ardhyani, (2018), Perencanaan Pemeliharaan Mesin Produksi Dengan Menggunakan Metode Reliability Centered Maintenance (RCM) (Studi Kasus: PT. S), Journal Of Industrial and System Optimization, Vol 1, No 1.

Ferry Budhi Susetyo, Ragil Sukarno, Khulaifiyah, (2022), Analisis Perawatan Pada Komponen Mesin Degreaser Di PT.X, Jurnal Konversi Energi dan Manufaktur, Volume 7 Nomor 1 – Januari 2022 Halaman 17-26.

Farkhan Fajar Nurdin, (2023), Peningkatan Produktivitas Peralatan dan Perawatan Mesin Total Productive Maintenance (TPM) menggunakan metode Overall Equipment Effectiveness (OEE), Pro siding SAINTEK : Sains dan Teknologi Vol. 2 No.1.

Francisco Javier, Álvarez García and David Rodríguez Salgado, (2022), An Approach for Predictive Maintenance Decisions for Components of an Industrial Multistage Machine That Fail before Their MTTF: A Case Study, Journal Systems MDPI, Volume 10 Page 175.

Francisco Javier Álvarez García, and David Rodríguez Salgado, (2022), Analysis of the Influence of Component Type and Operating Condition on the Selection of Preventive Maintenance Strategy in Multistage Industrial Machines: A Case Study, Journal Machine MDPI, Volume 10, Page 385.

Francisco Javier Álvarez García and David Rodríguez Salgado, (2021), Maintenance Strategies for Industrial Multi-Stage Machines: The Study of a Thermoforming Machine, Journal Sensors MDPI, Volume 21, Page 6809.

Francisco Javier Álvarez García and David Rodríguez Salgado, (2022), An Approach for Predictive Maintenance Decisions for Components of an Industrial Multistage Machine That Fail before Their MTTF: A Case Study, Journal System MDPI, Volume 10 (5), Page 175.

Jacob Sawai Ben, (2022), Implementation of Autonomous Maintenance and its Effect on MTBF, MTTR, and Reliability of a Critical Machine in a Beer Processing Plant, International Journal of Progressive Sciences and Technologies (IJPSAT), Vol. 31 No. 1, pp. 57-66.

Jun Junaedi, Tasya Aspiranti, Eka Tresna Gumelar, (2021), Analisis Pemeliharaan Mesin Produksi Panel Surya dengan Menggunakan Metode MTBF, MTTF, MTTR untuk Meminimumkan Biaya Maintenance, Bandung Conference Series: Business and Management.

Kamil Daniewski, Ewelina Kosicka, Dariusz Mazurkiewicz, (2018), Analysis Of The Correctness Of Determination Of The Effectiveness Of Maintenance Service Actions, Journals Pan, Volume 9 Number 2, pp. 20–25.

Kartick Bhushan, Somnath Chattopadhyaya, Shubham Sharma, Kamal Sharma, Changhe Li, Yanbin Zhang and Elsayed Mohamed Tag Eldin, (2022), Analyzing Reliability and Maintainability of Crawler Dozer BD155 Transmission Failure Using Markov Method and Total Productive Maintenance: A Novel Case Study for Improvement Productivity, Journal Sustainability MDPI, Volume 14, Page 14534.

Marina Rezende, Rogério Santos, Fernando Coelli and Renan Almeida, (2023), Reliability Analysis Techniques Applied to Highly Complex Medical Equipment Maintenance, Journal EasycChair Preprint No 10776.

Muhammad Arizki Zainul Ramadhan, (2018), Penentuan Interval Waktu Preventive Maintenance Pada Nail Making Machine Dengan Menggunakan Metode Reliability Centered Maintenance (Rcm) Ii (Studi Kasus : PT. Surabaya Wire), Universitas Muhammadiyah Sidoarjo.

Nova Ardyanto, (2020), Analisa Manajemen Pemeliharaan Peralatan Induce Draft Fan (Idf) Pltu Dengan Pendekatan Life Cycle Cost, Journal UII.

Rafal Drewniak, Zbigniew Drewniak, (2022) Improving business performance through TPM method: The evidence from the production and processing of crude oil, PLOS ONE, Volume 10, Page 1371.

Stanisław Duer, Marek Wo´zniak, Jacek Pa´s, Konrad Zajkowski, Dariusz Bernatowicz, Arkadiusz Ostrowski and Zbigniew Budniak, (2023), Reliability Testing of Wind Farm Devices Based on the Mean Time between Failures (MTBF), Journal Energies, Volume 16, Page 1659.

Restu Harywibowo, (2022), Pengaruh Pemeliharaan Preventif, Manajemen Trafic, Dukungan Teknologi Dan Komunikasi Dan Kepedulian Operator Terhadap Kinerja K3 Transportasi Unit Truck Di Perusahaan Jasa Pertambangan Pt. XYZ, Universitas Mercu Buana.

Smith, R. (2004). Maintenance and Reliability Best Practices. CRC Press.

Wireman, T. (2004). Total Productive Maintenance. Industrial Press Inc.

Yulien Gidion Rukmana Hermanto, (2021), Interval Preventive Maintenance Dengan Dasar Keandalan, Institut Teknologi Sepuluh Nopember.