Teknik Keandalan dan Perawatan

Irwan Pambudi Fakultas Teknik Jurusan Teknik Industri

 Ruang lingkup, istilah-istilah dan definisi, serta klasifikasi sistem perawatan Klasifikasi sistem, criticality determination, serta design sistem perawatan. Rumus-rumus matematika, jenis fungsi distribusi, fungsi keandalan dan laju kerusakan Bathub hazard rate curve Pemahaman keandalan sebuah system, metode-metode analisa, dan fungsi keterawatan Pemahaman point-point peningkatan kualitas deming, metode continuous improvement (CI), Reliability Centered Maintenance (RCM)

Traditional view of equipment failure...

The Reality of Failure...

Function and Failures

Functions
How does it work and what performance standards do the users want from the equipment in its present operating context?

Functional Failures
In what ways does it fail to do what the users want?

Failure Modes
What exactly causes each functional failure?

Failure Effects
What happens when each failure occurs?

Where to Start?

What is Criticality?
A tool to establish:
Which equipment has the greatest impact on the business when it fails. Which equipment has the greatest safety or environmental risk associated with its failure.

Used in industries where failures have:

Severe safety/environmental consequences. Big impact on production output.

Importance's
We can use criticality as a decision making tool for:
Plant configuration and standby redundancy. Equipment we should maintain. The maintenance techniques that we apply to equipment. The level of maintenance that we apply to equipment. Scheduling maintenance work orders. Identifying equipment we stock spares for.

Criticality and Priority

While all equipment is important, some is more important In manufacturing, criticality can only be measured in terms of its impact to the entire productions system
Criticality depends on many factors, and generally requires some analysis to identify Factors include: Capacity Process Capability Safety or environmental considerations Reliability, etc

Criticality Factor Definitions

Control Point The machine which has least capacity in the process

Process capability The ability of the process to produce parts that conform to engineering specification (Cpk)
Reliability Probability product performs intended function for specified length of time (Mean Time Between Failure / MTBF) Maintainability Ease and/or cost of maintaining/repairing product (Mean Time To Repair / MTTR) System Availability =
MTBF MTBF + MTTR

Generic maintenance policies can be developed for most types of physical assets

Criticality

Equipment Criticality
Highest Criticality Band 5 - covers top 20 assets, apply RCM technique and develop best maintenance practice.
Criticality Band 4 - covers top 21-100 assets, could apply RCM technique and develop best maintenance practice. Criticality Bands 3 & 2 - develop Preventive Maintenance Routines (PMRs). Criticality Band 1 - no preventive maintenance - Run to Breakdown, any breakdown will have insignificant impact on the business.

Priority levels
Priority Level

Description
This priority to be used when an immediate response is required, ie safety work, environmental, product quality threatening or process critical equipment failure, and the work request should be actioned during the shift in which it is received. This priority to be used when the work must be performed within the current scheduled period and has been designated as a higher priority than any other job planned for this period This priority to be used for work which requires planning or can wait until the next schedule period, typically 5 or more days away. Included in this category are planned and predictive maintenance activities. This priority to be used to plan work for shutdown periods and should be used in conjunction with a completion date. Or it can be used for non-critical work to be completed when there is no priority 2 4 work available. Included in this category are project support and training activities.

3 2

Planning & Scheduling

Criticality the product rule

Criticality is calculated from the product of a number of variables: 1. 2. 3. 4. 5. Output Quality Repair cost Utilisation Frequency of breakdown

Severity x Probability x

6. 7.

Safety and Health Environmental

Safety and Health Factors

Scoring System & Rules

MP2 data from 2005 to May 2007 are used as main consideration for calculating Breakdown duration, Frequency, and Repair cost. Historical and Judgment are used for scoring Quality, Health & Safety, and Environmental. Buffer stock and temporary solution are not included in the calculations.

Scoring Guidance - 1
1. Output All product output from different perspective are bring into one common measures i.e in cigarette sticks per minute -> the output is equal to sticks / minutes x average Breakdown in minutes
1 No Effect 2 <20 million products 3 20-80 million products 4 80-200 million products 5 >200 million products

Scoring Guidance - 2
2. Quality
1 No Effect 2 Additional work required to prevent loss of product quality 3 Lower grade product produced 4 Material reprocessed 5 Product reject or material contaminated

3. Repair cost
1 <US$500 2 US$500-US$2,000 3 US$2,000-US$5,000 4 US$5,000-US$10,000 5 >US$10,000

Repair cost =

spare part cost breakdown

Scoring Guidance - 3
4. UtilizationUtilization =
1 <20% 2 20%-40% 3 40%-60% 4 60%-80% 5 >80%
working time calendar time

Forecast
(design capacity*working time*uptime)

5. Breakdown Frequency
1 <3 per year 2 4-24 per year 3 25-36 per year 4 36-52 per year 5 >52 per year

Scoring Guidance - 4
6. Health & Safety
1 No effect 2 First aid/visit to site health center 3 Treatment required (TRI / LWD 1-3 days) 4 Lost working days > 3 days 5 Long term absence. LWD > 2 months 6 Single fatality or permanent disablement 7 Multiple fatality

Scoring Guidance - 5
6. Environmental
1 No effect 2 Investigation release of hazardous material not infringing regulation at factory perimeter (local requirement meet) 3 Complaint or breach of regulation 4 Major breach of regulation 5 Business interruption for 1 day probably a prohibition notice 6 Business interruption 1 day 1 week 7 Business interruption 1 week lost production permit

Define what maintenance has to be done and how it will be measured

Carry out criticality on all assets to identify their individual impact on the business should they fail. Establish 5 Criticality Bands
Highest Criticality - Band 5 Apply RCM techniques and develop best maintenance practice. Conducted on top 20 most critical assets. Review Preventive Maintenance Routines (PMRs) using REM technique. Criticality - Band 4, 3 & 2: Develop and/or review Preventive Maintenance Routines (PMRs) using REM technique. Criticality - Band 1: No preventive maintenance, unless covered by statutory requirements. No preventive maintenance other than minor lubrication and cleaning.

Asset Registration
Asset Register : A definitive list of equipment, facilities and/or systems which are supported by the maintenance function The maintenance function may be in-house or externally resourced. The term asset is often used for equipment, facilities and/or systems. Scope : All plant, facilities and systems referred to as assets which are to be maintained, down to the lowest maintainable item (if appropriate). Any item which is not maintained but replaced ie. a seal, bearing, or a fuse is listed in the Bill of Materials (BoM) and not listed in the asset register.

Key Reasons
To get better maintenance performances in :
1. Maintenance Management 2. Reporting 3. Information/Data

Structure
By using a logical structure an asset register should: Provide easy browsing for all users. Enable Computer Maintenance Management System (CMMS) to simplify links to Planned Maintenance Routines (PMRs). Include assets and, via CMMS, functional locations which planned and unplanned activities could be booked against. Have a consistent hierarchical structure throughout the Asset Register.

Correspond with the financial cost centre /capex code, whether by area, Department owner or user, or a combination of these factors.

Asset Hierarchy
Lv-0 Corporate
SAMPOERNA OPERATION Manufacturing operating

Lv-1 Area
PANDAAN

Lv-2 Group
PRODUCTION

Lv-3 Building
SKM1

Lv-4 Line/Function L12 Lv-5 Equipment PACK-0027 Lv-6 Subassembly

X2 CH MAKE-0002 CBAN-0247 CFED-0078 F11 F12 D11 TRC

PP01 CP01 GLT1

UTILITY
FACILITY SURABAYA

Utilities & FMG

Level 3 LT47 APTK ATB1 BBK2 CMST CP01 GR02 GR03 GR06 GRST GTES GTTC LT37 LT39 LT48 LTST MOS1 MSPT PP02 PPCP PUMH PWRH PWRP SK1-2
Level 4 AIRC BOIL CCTV COMP Delta EFAN FFST FURN LIFT LPRO OHSM PNLV PNMV PRTL UPSO VACC WTST WWTP Exhaust Fan Fire Fighting System Furnace Lift Lighting Protection Oil Heating System Panel Low Voltage Panel Medium Voltage Portal Electrical Storage Vacuum Fresh Water Waste Water

Utility
DESCRIPTION Air Conditioner Boiler Close Circuit TV Compressor Level 4 ASPL CURB DRNG HLMN HLTE KNTN KOPR MTRM PLKN RUAG UNT1 UNT2 UNT3 UNT4 UNT5 UNT6 UNT7 UTLT

FMG
DESCRIPTION Aspalt Curb Drainage Halaman Halte Kantin Koperasi Meeting Room Poliklinik Ruangan UNIT 1 UNIT 2 UNIT 3 UNIT 4 UNIT 5 UNIT 6 UNIT 7 / FGW Utility

CP02
CPLT DELT DIET FGWH FMG FURN GETS GLT1 GLT2 GR01

LCLV
LT04 LT07 LT08 LT08 LT15 LT17 LT21 LT30 LT33 LT35

MSST
PCTL PDEV PHR1 PHR2 PLOT PMK1 PMK2 POLI POSK PP01

SKM1
SKM2 SKM3 SKM4 SPM SPM 2 SPM1 SPP1 SPP2 WWTP