2. Kegagalan (Failure)
Failure – ketidakmampuan untuk melakukan kerja dengan
appropriate manner
Equipment / machine failure on production floor – worn
out bearing, pump, pressure leaks, broken shaft,
overheated machine etc.
Equipment failure in office – failure of power supply, air-
conditioned system, computer network, photocopy
machine
Vehicle failure – brake, transmission, engine, cooling
system
3. Konsekuensi Permasalahan Mesin
Masalah Mesin Dampak Langsung Biaya / Konsekuensi Akhir
Malfunction Deteriorasi mesin Umur mesin singkat
Ketidakefisienan mesin Biaya perbaikan tinggi
Variabilitas output Scrap dan rework
Breakdown Bahaya keselamatan Cedera
Pekerja menganggur Persediaan
Fasilitas menganggur Biaya perbaikan tinggi
Penundaan jadwal
4. Pemeliharaan (Maintenance)
Semua aktivitas untuk memelihara fasilitas dan mesin
serta peralatan bekerja dengan baik sehingga sistem
dapat bekerja sebagaimana dimaksudkan
Meliputi: servicing, repair, modification, overhaul,
inspection and condition verification
Increase availability of a system
Keep system’s equipment in working order
6. Tujuan Pemeliharaan
Upaya untuk memaksimalkan kinerja mesin dan
peralatan secara efisien dan teratur
Prevent breakdown or failures
Minimize production loss from failures
Increase reliability of the operating systems
7. Tujuan Dasar Pemeliharaan
(Principle Objectives in Maintenance)
Mencapai kualitas produk dan kepuasan pelanggan
melalui adjusted and serviced equipment
Memaksimalkan usia pemakaian mesin dan peralatan
Menjaga mesin dan peralatan aman dan mencegah
bahaya keselamatan
Meminimasi frekuensi dan lamanya interupsi atau
gangguan
Memaksimalkan kapasitas produksi – melalui utilisasi
tinggi fasilitas
8. Permasalahan dalam Pemeliharaan
Kurangnya perhatian manajemen pada pemeliharaan
Rendahnya partisipasi accounting dalam analisis dan
melaporkan berbagai jenis biaya
Kesulitan dalam menerapkan analisis kuantitatif
Kesulitan dalam mendapatkan estimasi waktu dan
biaya untuk pekerjaan pemeliharaan
Kesulitan dalam pengukuran kinerja
9. Maintenance Costs
Cost to replace or repair
Losses of output
Delayed shipment
Scrap and rework
10. Tipe Pemeliharaan
Reactive or Corrective Maintenance:
Breakdown maintenance
Reactive approach; dealing with breakdowns or problems
when they occur
Proactive Maintenance:
Preventive maintenance
Proactive approach; reducing breakdowns through a
program of lubrication, adjustment, cleaning, inspection,
and replacement of worn parts
11. Corrective or Breakdown Maintenance
Perbaikan dilakukan setelah mesin dan peralatan
rusak dan tidak dapat melakukan fungsinya secara
normal lagi
Dapat dibenarkan untuk pabrik kecil dimana:
Waktu kerusakan bersifat tidak kritis dan biaya perbaikan
lebih rendah dari tipe pemeliharaan lainnya
Alasan keuangan untuk penjadwalan tidak ada
12. Kerugian Corrective Maintenance
Breakdown generally occurs inappropriate times leading to
poor and hurried maintenance
Excessive delay in production & reduces output
Faster plant deterioration
Increases chances of accidents and less safety for both
workers and machines
More spoilt materials
Direct loss of profit
13. Scheduled Maintenance
Scheduled maintenance is a stitch-in-time procedure and
incorporates
inspection
lubrication
repair and overhaul of equipment
If neglected can result in breakdown
Generally followed for:
overhauling of machines
changing of heavy equipment oils
cleaning of water and other tanks etc.
14. Preventive Maintenance (PM)
Prinsip – “Prevention is better than cure”
Prosedur - Stitch-in-time
It
locates weak spots of machinery and equipment
provides them periodic/scheduled inspections and
minor repairs to reduce the danger of unanticipated
breakdowns
15. Candidates for Preventive Maintenance
Mean Time Between Failure (MTBF)
Frequency of Failure
Good candidates
have more normal
distribution with
low variability
16. Keuntungan PM
Reduces break down and thereby down time
Less odd-time repair and reduces over time of crews
Greater safety of workers
Lower maintenance and repair costs
Less stand-by equipment and spare parts
Better product quality and fewer reworks and scraps
Increases plant life
Increases chances to get production incentive bonus
17. Kunci Keberhasilan Sistem PM
Scheduling – Should be automated to the maximum
extent possible
Execution – Should be done before the actual break
down occurs.
18. Execution
The Bath Tub Model – Three
stages of new parts
1. Infant mortality stage
2. A fairly long run stage
3. Wear out stage
Traditional View according to
Bath Tub Model – Replace
components just before they
entered wear out stage
19. Execution
Traditional view says –
Wear out stage = Increased rate of failure.
Point to Ponder –
Since, wear out stage represents increased rate of failure,
wouldn’t it be plausible to execute the PM program at this
stage?
20. Fokus PM
Cleaning Found through testing
Lubrication and inspection
And correcting deficiencies
Predetermined parts replacement should be minimal and done only where statistical evidence clearly
indicates wear-out characteristics
21. Predictive (Condition-based) Maintenance
In predictive maintenance, machinery conditions are
periodically monitored and this enables the
maintenance crews to take timely actions, such as
machine adjustment, repair or overhaul
It makes use of human sense and other sensitive
instruments, such as
audio gauge, vibration analyzer, amplitude meter, pressure,
temperature and resistance strain gauges etc.
22. Predictive Maintenance (Contd.)
Unusual sounds coming out of a rotating equipment
predicts a trouble
An excessively hot electric cable predicts a trouble
Simple hand touch can point out many unusual
equipment conditions and thus predicts a trouble
27. Total Productive Maintenance (TPM)
Komitmen untuk melakukan pemeliharaan melebihi preventive and
predictive maintenance.
Semua pekerja terlibat dalam pemenuhan kepuasan pelanggan,
dimana pelanggan didefinisikan sebagai tahapan berikut dari sebuah
proses
Suatu kerusakan mesin dilihat sebagai defect, dan TPM berkomitmen
untuk mencegah breakdown and malfunction
TPM merupakan aspek lanjutan dari continous improvement, yang
merupakan proses mengedukasi dan melibatkan pekerja, upgrading
and redesigning equipment, penerapan foolproofing devices,
memonitor kinerja mesin dan peralatan, dan mengeliminasi sumber-
sumber pemborosan mesin dan peralatan
28. Total Productive Maintenance (TPM)
TPM merupakan Japanese approach untuk
• Membuat budaya perusahaan untuk efisiensi
maksimum
• Upaya mencegah kerugian dengan biaya minimum
– Zero breakdowns and failures, Zero accident, and Zero
defects etc
• Esensi kerja tim (aktivitas kelompok kecil) berfokus
pada kondisi dan performansi fasilitas-fasilitas
untuk mencapai zero loss for improvement
• Keterlibatan semua SDM mulai dari top
management hingga operator
29. TPM
Production Operators
• Clean & Check
• Observe
• Categorize
Manufacturing Engineers
• Equipment Planning
• Equipment Studies
Production Planning &
Control
• Schedule P.M.
Quality Engineers
• Standards &
Calibrations
Active
Planned
Maintenance
Process
31. A Socio-Technical System
Manufacturing (and many other) systems have both technical and
human/social aspects that are tightly bound and interconnected.
Moreover, it is the interconnections more than individual elements that
determine system performance.
The technical system includes machinery, processes, procedures and
a physical arrangement. We usually think of a factory in terms of its
technical system.
The social system includes people and their habitual attitudes, values,
behavioral styles and relationships. It includes the reward system. It is
the formal power structure as depicted on organization charts and the
informal power structure deriving from knowledge and personal
influence.
32. Hasil Penerapan TPM
3M reduced their maintenance cost by 60% within three years.
DuPont reduced off-quality by 69% and improved capacity by
29% in three years.
Harley-Davidson estimates that the ROI from TPM has been
ten-fold to the cost of implementation.
Kodak reported a $5 million investment in TPM that resulted in
a $16 million increase in profits.
