Usulan Kebijakan Perawatan Pada Mesin Pompa Cosorb P201 Dengan Menggunakan Metode Reliability Centered Maintenance (rcm) Di Pt Ans
Abstract
Abstrak
PT ANS merupakan salah satu perusahaan yang memproduksi pupuk di Indonesia. Mesin
pompa COSORB P-201 merupakan mesin yang digunakan oleh PT ANS untuk memproduksi
pupuk dan beroperasi selama 24 jam/hari, 7 hari/minggu. Permasalahan yang sering terjadi di
PT ANS terdapat pada mesin pompa COSORB P-201 dengan jumlah kerusakan 70 kali
selama 2017 sampai 2019. Oleh karena itu, perusahaan menerapkan kegiatan preventive
maintenance dan corrective maintenance untuk memastikan kinerja mesin pompa COSORB P- 201 tetap bekerja sesuai fungsinya. Tujuan dari penelitian ini untuk menentukan interval
waktu perawatan dan estimasi biaya perawatan yang efisien. Metode yang dipilih yaitu
Reliability Centered Maintenance (RCM) kemudian menggunakan analisis Failure Mode Effect
and Critical Analysis (FMECA) untuk mendapatkan output berupa nilai RPN pada komponen
kritis yang terpilih pada sistem yaitu bearing ball, mechanical seal, dan impeller. Berdasarkan
hasil pengumpulan dan pengolahan data menggunakan RCM Worksheet kemudian ditentukan
kebijakan perawatan dengan hasil 2 scheduled on-condition task, 1 scheduled restoration task, dan 3 scheduled discard task dengan masing-masing interval waktu perawatan sesuai kategori
tasknya. Total biaya perawatan usulan sebesar Rp500.802.048 untuk satu tahun, menghemat
biaya perawatan sebesar Rp29.458.944 dibandingkan biaya perawatan aktual. Kata Kunci: Maintenance, Reliability Centered Maintenance, Failure Mode Effect and Critical
Analysis, RCM Worksheet, Maintenance Cost.
Abstract
PT ANS is a company that produces fertilizer in Indonesia. The COSORB P-201 pumping
machine is a machine used by PT ANS to produce fertilizer and operates 24 hours
continuously. Problems that often occur in PT ANS are on the COSORB P-201 pumping
machine with 70 times amount of damage during 2017 to 2019. Therefore, the company
implements preventive maintenance and corrective maintenance to ensure the COSORB P-201
pumping machine’s performance to keep working in accord with its function. The purpose of
this study was to determine the treatment time interval and the estimated cost of ef icient
maintenance. So the method chosen in this study was Reliability Centered Maintenance (RCM)
which used the Failure Mode Effect Analysis and Critical Analysis (FMECA) to obtain an
output in the form of RPN values on the critical components which selected in the system, namely ball bearings, mechanical seals, and impellers. Based on the results of data collection
and data processing using the RCM Worksheet then maintenance policies are determined with
the results of 2 scheduled on-condition tasks, 1 scheduled restoration and 3 scheduled discard
tasks with maintenance time intervals according to each task category. The total cost of
proposed treatment was Rp 500.802.048. The dif erence in actual maintenance costs and
proposed maintenance costs can save maintenance costs by Rp 29.458.944. Keywords : Maintenance, Reliability Centered Maintenance, Failure Mode Effect and Critical
Analysis, RCM Worksheet, Maintenance Cost.
PT ANS merupakan salah satu perusahaan yang memproduksi pupuk di Indonesia. Mesin
pompa COSORB P-201 merupakan mesin yang digunakan oleh PT ANS untuk memproduksi
pupuk dan beroperasi selama 24 jam/hari, 7 hari/minggu. Permasalahan yang sering terjadi di
PT ANS terdapat pada mesin pompa COSORB P-201 dengan jumlah kerusakan 70 kali
selama 2017 sampai 2019. Oleh karena itu, perusahaan menerapkan kegiatan preventive
maintenance dan corrective maintenance untuk memastikan kinerja mesin pompa COSORB P- 201 tetap bekerja sesuai fungsinya. Tujuan dari penelitian ini untuk menentukan interval
waktu perawatan dan estimasi biaya perawatan yang efisien. Metode yang dipilih yaitu
Reliability Centered Maintenance (RCM) kemudian menggunakan analisis Failure Mode Effect
and Critical Analysis (FMECA) untuk mendapatkan output berupa nilai RPN pada komponen
kritis yang terpilih pada sistem yaitu bearing ball, mechanical seal, dan impeller. Berdasarkan
hasil pengumpulan dan pengolahan data menggunakan RCM Worksheet kemudian ditentukan
kebijakan perawatan dengan hasil 2 scheduled on-condition task, 1 scheduled restoration task, dan 3 scheduled discard task dengan masing-masing interval waktu perawatan sesuai kategori
tasknya. Total biaya perawatan usulan sebesar Rp500.802.048 untuk satu tahun, menghemat
biaya perawatan sebesar Rp29.458.944 dibandingkan biaya perawatan aktual. Kata Kunci: Maintenance, Reliability Centered Maintenance, Failure Mode Effect and Critical
Analysis, RCM Worksheet, Maintenance Cost.
Abstract
PT ANS is a company that produces fertilizer in Indonesia. The COSORB P-201 pumping
machine is a machine used by PT ANS to produce fertilizer and operates 24 hours
continuously. Problems that often occur in PT ANS are on the COSORB P-201 pumping
machine with 70 times amount of damage during 2017 to 2019. Therefore, the company
implements preventive maintenance and corrective maintenance to ensure the COSORB P-201
pumping machine’s performance to keep working in accord with its function. The purpose of
this study was to determine the treatment time interval and the estimated cost of ef icient
maintenance. So the method chosen in this study was Reliability Centered Maintenance (RCM)
which used the Failure Mode Effect Analysis and Critical Analysis (FMECA) to obtain an
output in the form of RPN values on the critical components which selected in the system, namely ball bearings, mechanical seals, and impellers. Based on the results of data collection
and data processing using the RCM Worksheet then maintenance policies are determined with
the results of 2 scheduled on-condition tasks, 1 scheduled restoration and 3 scheduled discard
tasks with maintenance time intervals according to each task category. The total cost of
proposed treatment was Rp 500.802.048. The dif erence in actual maintenance costs and
proposed maintenance costs can save maintenance costs by Rp 29.458.944. Keywords : Maintenance, Reliability Centered Maintenance, Failure Mode Effect and Critical
Analysis, RCM Worksheet, Maintenance Cost.
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