Usulan Planned Maintenance Menggunakan Metode Opportunity Based Maintenance untuk Mereduksi Downtime
DOI:
https://doi.org/10.29313/bcsies.v6i1.23362Keywords:
Opportunity Based Maintenance, Reliability, Mean Time Between Failure (MTBF)Abstract
Abstract. PT Bukit Asam is a coal mining company where the Jaw Crusher machine is essential in the size reduction process. Frequent failures of several components disrupt production, prompting this study to analyze the reliability of critical components and implement an Opportunity Based Maintenance (OBM) strategy. Four critical components were identified: moving jaw plate, fixed jaw plate, cheek plate, and flywheel. Failure data were analyzed using the Index of Fit method with normal, lognormal, exponential, and Weibull distributions for both Time to Failure (TTF) and Time to Repair (TTR). The Mean Time Between Failure (MTBF) values were: 676.64 hours (moving jaw plate), 672.23 hours (fixed jaw plate), 905.82 hours (cheek plate), and 1284.31 hours (flywheel). Reliability at failure time ranged from 42.07% to 49.6%. The OBM model, processed using Microsoft Excel Solver, produced a system reliability of R = 1. This indicates that all critical components can undergo preventive maintenance simultaneously during planned downtime. A total of 12 scheduled maintenance cycles were determined from January 1, 2024, to February 8, 2027, based on MTBF values. This strategy is projected to reduce unplanned failures and minimize maintenance costs, with an estimated failure cost of IDR 167.563.810.
Abstrak. PT Bukit Asam merupakan perusahaan tambang batubara di mana mesin Jaw Crusher berperan penting dalam proses pengecilan ukuran material sebelum tahap pengolahan selanjutnya. Permasalahan yang terjadi adalah tingginya tingkat kerusakan pada beberapa komponen mesin yang mengganggu aktivitas produksi. Penelitian ini bertujuan untuk menganalisis keandalan komponen kritis dan menerapkan strategi perawatan dengan metode Opportunity Based Maintenance (OBM) guna meningkatkan efektivitas sistem pemeliharaan mesin. Komponen kritis yang dianalisis meliputi moving jaw plate, fixed jaw plate, cheek plate, dan flywheel. Analisis distribusi kerusakan dilakukan menggunakan metode Index of Fit terhadap data Time to Failure (TTF) dan Time to Repair (TTR) dengan empat jenis distribusi: normal, lognormal, eksponensial, dan Weibull. Nilai Mean Time Between Failure (MTBF) adalah: moving jaw plate 676,64 jam, fixed jaw plate 672,23 jam, cheek plate 905,82 jam, dan flywheel 1284,31 jam. Keandalan saat waktu kerusakan berkisar antara 42,07% hingga 49,6%. Model OBM yang diolah menggunakan Microsoft Excel Solver menghasilkan nilai keandalan sistem R = 1, artinya seluruh komponen dapat dilakukan preventive maintenance secara bersamaan saat mesin utama berhenti. Penjadwalan perawatan direncanakan sebanyak 12 kali dari 1 Januari 2024 hingga 8 Februari 2027. Strategi ini diperkirakan mampu menekan kerusakan mendadak dan mengurangi biaya perawatan, dengan total biaya kegagalan sebesar Rp 167.563.810.
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