Preventive Maintenance pada Slag Hauler dengan Metode Reliability Centered Maintenance (RCM) dan Failure Mode and Effect Analysis (FMEA)

Dalam industri smelter, keandalan alat berat seperti Slag Hauler sangat berpengaruh terhadap kontinuitas produksi. Kegagalan alat ini dapat menyebabkan downtime yang tinggi dan potensi kerugian besar. Penelitian ini bertujuan untuk meningkatkan efektivitas perawatan Slag Hauler dengan menerapkan metode Reliability Centered Maintenance (RCM) dan Failure Mode and Effect Analysis (FMEA) pada unit SH-001.
Penelitian dilakukan melalui pengumpulan data downtime dan riwayat kerusakan komponen dari tim maintenance selama periode operasi 3.600 jam. Analisis RCM digunakan untuk menentukan strategi perawatan berdasarkan fungsi dan konsekuensi kegagalan, sedangkan FMEA digunakan untuk mengidentifikasi mode kegagalan dan menghitung Risk Priority Number (RPN) sebagai dasar prioritas perawatan. Perhitungan keandalan dilakukan dengan pendekatan distribusi eksponensial menggunakan parameter Mean Time To Failure (MTTF) dan laju kegagalan (λ).
Hasil penelitian menunjukkan bahwa komponen kritis penyebab utama downtime adalah Pegas Injektor Fuel, Bearing Tensioner, dan Seal O-Ring Silinder Kabin, dengan kontribusi lebih dari 65% terhadap total downtime. Nilai keandalan rata-rata unit SH-001 setelah 1.000 jam operasi sebesar 66%. Berdasarkan perhitungan, interval Preventive Maintenance (PM) optimal untuk Pegas Injektor Fuel adalah 1.819 jam, Bearing Tensioner 1.271 jam, dan Seal O-Ring Silinder Kabin 1.371 jam. Hasil FMEA menunjukkan nilai RPN tertinggi pada Pegas Injektor Fuel (32), Bearing Tensioner (24), dan Seal O-Ring Silinder Kabin (16).
Rekomendasi strategi perawatan berbasis RCM mencakup tiga kategori utama: Scheduled Restoration Task untuk penggantian periodik komponen utama, On-Condition Task untuk inspeksi kebocoran sistem hidrolik, dan Failure Finding Task untuk pemeriksaan komponen listrik serta sistem proteksi. Implementasi strategi ini diharapkan dapat menurunkan downtime hingga 30%, meningkatkan availability alat di atas 90%, serta menekan biaya perawatan reaktif sebesar 20–25%.

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In the smelter industry, the reliability of heavy equipment such as slag haulers significantly impacts production continuity Failure of this equipment can lead to high downtime and potentially significant losses. This study aims to improve the effectiveness of slag hauler maintenance by applying the Reliability-Centered Maintenance (RCM) and Failure Mode and Effect Analysis (FMEA) methods to the SH-001 unit.
The study was conducted by collecting downtime data and component failure history from the maintenance team over a
3,600-hour operating period. RCM analysis was used to
determine maintenance strategies based on function and failure consequences, while FMEA was used to identify failure modes and calculate the Risk Priority Number (RPN) as the basis for maintenance priorities. Reliability calculations were performed using an exponential distribution approach using the Mean Time To Failure (MTTF) and failure rate (A) distribution.
The results showed that the critical components causing downtime were the Fuel Injector Spring, Tensioner Bearing, and Cabin Cylinder O-Ring Seal, contributing more than 65% of the total downtime. The average reliability value for the SH-001 unit after 1,000 hours of operation was 66%. Based on the calculations, the optimal Preventive Maintenance (PM) interval for the Fuel Injector Spring was 1,819 hours, the Tensioner Bearing 1,271 hours, and the Cabin Cylinder 0-Ring Seal 1,371 hours. The FMEA results showed the highest RPN values for the Fuel Injector Spring (32), the Tensioner Bearing (24), and the cabin cylinder O-ring seal (16).
The recommended RCM-based maintenance strategy covers three main categories: Scheduled Restoration Tasks for periodic replacement of major components, On-Condition Tasks for hydraulic system leak inspections, and Failure Finding Tasks for electrical component and protection system inspections. Implementing this strategy is expected to reduce downtime by up to 30%, increase equipment avalability above 90%, and reduce reactif maintenance costs by 20-25%.