Post on 04-Apr-2018
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Teknik Keandalan danPerawatan
Irwan Pambudi
Fakultas Teknik – Jurusan Teknik Industri
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• 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)
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Traditional view of equipment failure...
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The Reality of Failure...
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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?
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Where to Start?
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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 it’s failure.
Used in industries where failures have:
– Severe safety/environmental consequences.
– Big impact on production output.
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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.
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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
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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 engineeringspecification (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
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Generic maintenance policies can be developed for most
types of physical assets
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Criticality
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Equipment Criticality Highest Criticality Band 5 - covers top 20 assets, apply
RCM technique and develop best maintenancepractice.
Criticality Band 4 - covers top 21-100 assets, couldapply RCM technique and develop best maintenance
practice.
Criticality Bands 3 & 2 - develop PreventiveMaintenance Routines (PMRs).
Criticality Band 1 - no preventive maintenance - Run toBreakdown, any breakdown will have insignificantimpact on the business.
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Priority levels
Priority Level Description
This priority to be used when an immediate response is required, iesafety work, environmental, product quality threatening or processcritical equipment failure, and the work request should be actionedduring 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 higherpriority than any other job planned for this period
This priority to be used for work which requires planning or can waituntil the next schedule period, typically 5 or more days away. Includedin this category are planned and predictive maintenance activities.
This priority to be used to plan work for shutdown periods and shouldbe used in conjunction with a completion date. Or it can be used fornon-critical work to be completed when there is no priority 2 – 4 workavailable. Included in this category are project support and training activities.
4
3
2
1
Planning & Scheduling
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Criticality – the product rule
• Criticality is calculated from the product of a number of variables:
1. Output
2. Quality
3. Repair cost
4. Utilisation
5. Frequency of breakdown
6. Safety and Health
7. Environmental
Severity
Probability
Safety and Health
Factors
x
x
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Scoring System & Rules
• MP2 data from 2005 to May 2007 are usedas 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.
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Scoring Guidance - 1
1. Output
• All product output from different perspectiveare bring into one common measures i.e in
cigarette sticks per minute -> the output isequal to sticks / minutes x averageBreakdown in minutes
1 → No Effect2 → <20 million products
3 → 20-80 million products
4 → 80-200 million products
5 → >200 million products
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Scoring Guidance - 2
2. Quality1 → No Effect
2 → Additional work required to prevent loss of product quality
3 → Lower grade product produced
4 → Material reprocessed5 → Product reject or material contaminated
3. Repair cost
1 → <US$5002 → 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 =Σspare part cost
Σbreakdown
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Scoring Guidance - 3
4. Utilization1 → <20%
2 → 20%-40%
3 → 40%-60%
4 → 60%-80%5 → >80%
5. Breakdown Frequency
1 → <3 per year2 → 4-24 per year
3 → 25-36 per year
4 → 36-52 per year
5 → >52 per year
Utilization = Σworking timeΣcalendar time
Forecast
(design capacity*working time*uptime)≈
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Scoring Guidance - 4
6. Health & Safety1 → 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
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Scoring Guidance - 5
6. Environmental1 → 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
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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.
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Asset Registration• Asset Register :
A definitive list of equipment, facilities and/or systems which aresupported by the maintenance function
– The maintenance function may be in-house or externallyresourced.
– The term ‘asset’ is often used for equipment, facilities and/or systems.
• Scope :
– All plant, facilities and systems referred to as ‘assets’ which are tobe 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 inthe asset register.
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Key Reasons
To get better maintenance performances in :
1. Maintenance Management
2. Reporting
3. Information/Data
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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.
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Asset HierarchyLv-0 Corporate
SAMPOERNA OPERATION
PANDAAN
PRODUCTION
UTILITY
FACILITY
SKM1
GLT1
SURABAYA
F11
CP01
PP01
D11
F12
TRC
L12
MAKE-0002
PACK-0027
CBAN-0247
CFED-0078
Lv-4 Line/FunctionLv-3 Building
Lv-2 Group
Lv-5 Equipment
X2
CH
Lv-1 Area
Lv-6 Subassembly
Manufacturing operating
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Utilities & FMG
Level 3
LT47 GR02 LT37 PP02
APTK GR03 LT39 PPCP
ATB1 GR06 LT48 PUMH
BBK2 GRST LTST PWRH
CMST GTES MOS1 PWRP
CP01 GTTC MSPT SK1-2
CP02 LCLV MSST SKM1
CPLT LT04 PCTL SKM2
DELT LT07 PDEV SKM3
DIET LT08 PHR1 SKM4
FGWH LT08 PHR2 SPM
FMG LT15 PLOT SPM 2
FURN LT17 PMK1 SPM1
GETS LT21 PMK2 SPP1
GLT1 LT30 POLI SPP2
GLT2 LT33 POSK WWTP
GR01 LT35 PP01
Level 4 DESCRIPTION
AIRC Air Conditioner
BOIL Boiler
CCTV Close Circuit TV
COMP Compressor
Delta
EFAN Exhaust Fan
FFST Fire Fighting System
FURN Furnace
LIFT Lift
LPRO Lighting Protection
OHSM Oil Heating System
PNLV Panel Low Voltage
PNMV Panel Medium Voltage
PRTL Portal
UPSO Electrical Storage
VACC Vacuum
WTST Fresh Water
WWTP Waste Water
Level 4 DESCRIPTION
ASPL Aspalt
CURB Curb
DRNG Drainage
HLMN Halaman
HLTE Halte
KNTN Kantin
KOPR Koperasi
MTRM Meeting Room
PLKN Poliklinik
RUAG Ruangan
UNT1 UNIT 1
UNT2 UNIT 2
UNT3 UNIT 3
UNT4 UNIT 4
UNT5 UNIT 5
UNT6 UNIT 6
UNT7 UNIT 7 / FGW
UTLT Utility
Utility FMG