WHY DO MACHINES FAIL?

Wajar
Aus (wear): scuffing, galling, fretting, abrasion
Lelah (fatigue)
Karat (corrosion)
Erosi (erosion)
Penuaan (aging)
Prematur
Pelumasan tidak bagus (kualitas, kuantitas pelumas, periode
penggantian pelumas tidak benar)
Kotor/kontaminasi
Overheated
Misalignment (pada kopling, bearing, belt, rantai)
Sifat material berubah??????
 WHY DO MACHINES FAIL?
Brinelling karena overloaded Overheated
WHY DO MACHINES FAIL?

Fatigue damage
 FAILURE PATTERN
Dahulu orang percaya bahwa semua kegagalan
komponen mengikuti bathtub curve
Ternyata bathtub curve tsb hanya mencakup 4% dari
populasi komponen (mis: bearings, connector, switches,
IC, PCB, etc)
Age related failure hanya 11%
Failure Rate

Start up Break down

cycle cycle

Useful life period

(wealth cycle)
Critical wear point

Time
 FAILURE PATTERN
Arti dari bathtub curve
Start up cycle: kerusakan terjadi karena ketidak
sempurnaan material, pengerjaan, pemasangan,
pelatihan operator. Pada saat awal komponen mesin
akan saling menyesuaikan karena berbagai ketidak
sempurnaan pembuatan (permukaan masih kasar yang
saling menghaluskan)
Useful life: mesin berproduksi dengan baik karena
komponen2nya sudah saling menyesuaikan
Break down cycle: komponen mengalami fatigue,
keausan berlebih, erosi, abrasi dlsb.
Bath tube curve cocok untuk komponen mekanik.
 FAILURE PATTERN

4% 7%

14%
2%

68%
5%

Age related failure (1, 2, 3) Age unrelated failure (4, 5, 6)

Artinya: komponen akan Artinya: komponen bisa

rusak ketika sudah tua gagal secara random, pada
saat masih muda maupun
sesudah tua
FAILURE PATTERN POPULATION
PERCENTAGE

1
2
3
4
5
6
 FAILURE PATTERN

1940 1950 1960 1970 1980 1990 2000

 Kategori Mesin/Peralatan Produksi

Ditinjau dari tingkat kerumitan, harga,

peranan dan resiko dalam suatu mata
rantai produksi, mesin digolongkan atas.
Critical
Essential (Potentially critical)
General Purpose (Non critical)
Kategori ini untuk menentukan strategi
perawatan yang cocok.
 Mesin Critical

Kalau rusak dapat membahayakan

Kalau rusak proses produksi terganggu
Investasi mahal
Biaya perbaikannya mahal (misal: high
speed turbine)
Waktu untuk perbaikan lama
 Mesin General Purpose

Kalau rusak tidak membahayakan

Kalau rusak tidak mengganggu proses
produksi
Investasi tidak mahal
Biaya perbaikan tidak mahal
Mempunyai unit cadangan
Tidak mengakibatkan kerusakan sekunder
 Mesin Essential (Potentially Critical)

Di antara mesin critical dan general

purpose.
 PERKEMBANGAN
STRATEGI PERAWATAN
Sebelum PD II rancangan mesin sederhana,
kokoh, berat, robust
Perawatan sederhana
Munculnya sistem produksi massal berarti
kerusakan mesin produksi dapat menimbulkan
kerugian besar
Bersamaan dgn itu, rancangan mesin
bertambah rumit, ringan, ramping
Perlu strategi baru dalam perawatan
 PERKEMBANGAN
STRATEGI PERAWATAN

Generasi kedua
-Availability lebih baik
-Umur peralatan lebih
Generasi pertama panjang
-Perbaiki kalau rusak -Efektifitas biaya lebih baik
Generasi ketiga
-Availability dan reliability lebih
baik
-Keselamatan lebih baik
-Kualitas produk lebih baik
-Tidak mencemari lingkungan
-Umur peralatan lebih panjang
-Efektifitas biaya lebih baik

1940 1950 1960 1970 1980 1990 2000

 PERKEMBANGAN
STRATEGI PERAWATAN

Generasi ketiga
-Pemantauan kondisi mesin
-Design for reliability and
maintainability
-Hazard studies
Generasi kedua
-Komputer kecil, cepat
-Overhaul terjadwal
-FMEA
-Sistem utk perencanaan dan
pengendalian kerja -Expert systems
Generasi pertama
-Komputer besar dan lambat -Multi tasking and teamworks
-Perbaiki kalau rusak

1940 1950 1960 1970 1980 1990 2000

 PERKEMBANGAN
FILOSOFI PERAWATAN
Break down (run to failure) maintenance : mesin
dioperasikan tanpa perawatan sampai kerusakan terjadi.
Kerusakan primer hampir selalu menimbulkan kerusakan
sekunder.
Preventive maintenance (PM) atau time base
maintenance: mesin dimaintain secara terjadwal
setelah beroperasi dalam jangka waktu tertentu.
Predictive (on condition based) maintenance (PdM):
kondisi mesin dipantau secara menerus. Bila terdeteksi
adanya ketidak normalan baru diambil tindakan.
Proactive (prevention) maintenance: kerusakan yang
terjadi dicari penyebabnya untuk mencegah kerusakan
yang sama berulang.
 PERKEMBANGAN
FILOSOFI PERAWATAN
Strategy Reactive, Preventive Predictive Proactive
Run To Failure Maintenance Maintenance Maintenance
Definition Fix it when it Conduct Maintain based Redesign to
breaks, Run to maintenance at upon known eliminate root
Failure regular intervals condition/standard cause of failure
Advantages Cheap Can be planned Can spot potential Less
(when for or scheduled failure maintenance
implemented required
correctly)
Disadvantages High spare Unnecessary Costly if Could be
(when stock level. replacement of implemented expensive
implemented Emergency parts. Poor incorrectly
correctly) outages utilization of labor.
Component you Head light Oil change Automobile tires 2 year lease
would maintain
 Run-to-Failure Maintenance

Run-to-failure maintenance is sometimes

called "crisis maintenance" for good
reason. This has been the dominant form
of maintenance for a long time, and its
costs are relatively high because of
unplanned downtime, damaged
machinery, and overtime expenditure.
 REACTIVE:
Trouble / Breakdown / RTF / M&R
Fix it when it breaks Run to failure

PREVENTIVE (PM): Functional Checks of Equipment

For Rotating Equipment:
Lubrication
Belts
Filters
Housekeeping
Visual Observations
Work Orders generated Facility Asset Management
Information System
Periodic Preventive Maintenance
Periodic preventive maintenance, which is sometimes called
"historical" maintenance. This is where the histories of each
machine type are analyzed and periodic overhauls are scheduled to
occur before the statistically expected problems occur. It has long
been known that most groups of similar machines will exhibit failure
rates that are somewhat predictable if averaged over a long time.
This gives rise to the so-called "Bathtub Curve" which relates failure
rate to operating time, as follows:
 PREVENTIVE MAINTENANCE
(TIME BASED)
Preventive maintenance adalah suatu tindakan untuk
menjaga agar peralatan tetap dapat beroperasi dengan
cara inspeksi, deteksi dan pencegahan kerusakan.
Semua kegiatan perawatan dijadwal berdasar waktu
(mingguan, bulanan, triwulanan, 1000 jam, 3000 jam
dlsb)
Pelaksanaan mudah, tinggal mengikuti jadwal:
pembersihan, pengecatan, pelumasan, pemeriksaan,
perbaikan.(Rencana dan jadwal tahunan harus
disiapkan).
Penganggaran mudah: anggaran umumnya dibuat
tahunan.
 PREVENTIVE MAINTENANCE
(TIME BASED)
Murphy Law: Kerusakan biasanya terjadi pada waktu
peralatan sangat dibutuhkan.
Contoh: Pada saat banyak order, peralatan produksi
rusak. Perbaikan dapat memakan waktu beberapa jam
atau beberapa hari.
Hal yang tidak menguntungkan ini dapat dicegah dengan
PM.
Alasan lain: keselamatan, penghematan biaya perbaikan
karena kerusakan sekunder.
 PREVENTIVE MAINTENANCE
(TIME BASED)
Peralatan apa yang cocok untuk di PM?
Peralatan yang menyebabkan :
major shut down,
penurunan kualitas produk,
kerusakan terhadap komponen terkait,
bahaya kepada karyawan
Penerangan, lantai, plafon yang dapat mengganggu
kualitas produksi atau menimbulkan kondisi kerja yang
buruk.
 PREVENTIVE MAINTENANCE
(TIME BASED)
Peralatan apa yang tidak perlu di PM? (cukup dg RTF)
Peralatan yang mempunyai cadangan
Peralatan yang harganya lebih rendah dari biaya PM
Peralatan yang umur harapannya cukup panjang tanpa
PM
 Example
3 pumps of exactly the same type and manufacturer, however, each
requires different maintenance strategy.
Pump A: Preventive maintenance (PM)
Pump B: Break down maintenance (RTF)
Pump C: Periodic test to eliminate hidden failure or PM

Pump A (continuous Production Train 1

running) 100 l/min cooling Loss USD 200,000./day
water when stop

Pump B (continuous
running)
Production Train 1
Loss USD 200,000./day
Pump C (standby, 100 l/min cooling when stop
hidden failure) water
 Example
3 pumps of exactly the same type and manufacturer
Pump A: Predictive maintenance ???
Pump B: Break down maintenance???
Pump C: Periodic test???

Pump A (continuous Production Train 1

running) 100 l/min nitric acid Loss USD 200,000./day
when stop

Pump B (continuous
running)
Production Train 1
Loss USD 200,000./day
Pump C (standby, 100 l/min nitric when stop
hidden failure) acid
PREVENTIVE MAINTENANCE
(TIME BASED)
PM cost

Lebih banyak uang untuk PM, terjadi

sedikit keterlambatan

Lebih sedikit uang untuk PM,

terjadi banyak keterlambatan

% maintenance delay
PREVENTIVE MAINTENANCE
(TIME BASED)
Production cost as affected
Cost

by maintenance cost

Production cost due to delay

#1
PM cost #2
#3

% maintenance delay
 PREVENTIVE MAINTENANCE
(TIME BASED)
#1: terlalu banyak PM, menghamburkan tenaga, suku
cadang dan uang.
#2: sangat kurang, akan terjadi banyak kerusakan
#3: sangat optimum, tapi jarang tercapai. Indikasinya
20% peralatan mengalami kerusakan sebelum
diperbaiki.
Bila tidak terjadi kerusakan sebelum diperbaiki berarti
PM terlalu banyak.
 PREVENTIVE MAINTENANCE
(TIME BASED)
Rumus empirik untuk menentukan faktor PM (makin
tinggi nilainya PM makin perlu)
PM = D(A+B+C)/(EF)
PM = inspection factor
D = number of break down/year
A = cost of break down repairs
B = cost of lost production
C = cost of repairing other equipment involved in the
breakdown
E = cost of PM activity (average)
F = number of PM cycle per year
 PREVENTIVE MAINTENANCE
(TIME BASED)
Do PM (Preventive Maintenance) if number
of break down x Average cost per break
down x 70% > cost of PM system
 PREVENTIVE MAINTENANCE
(TIME BASED)
Optimum Frequency/Interval for PM ditentukan berdasar:
Failure history
CM history
Manufacturer recommendations
Industry history
Regulatory requirements
Design and operation considerations
Other tasks scheduled on the same component
Planned outages
Ability to gain access to the component
Operator capability
PdM monitoring activity
Environment
 PM Tasks
Type of Task Example
Inspection Look for leak in hydraulic system
Cleaning Remove debris from machines
Tightening Tighten anchor bolts
Operating Warming up machine/prepare for operation
Adjusting Adjust tightening bolt
Take reading Read temperature, pressure, vibration
Lubricate Add oil
Scheduled replacement Remove and replace pump
Analysis History analysis of a type of machine
Interview operator Ask operator how machine is operating
 PREVENTIVE MAINTENANCE
(TIME BASED)
Inspection
Memastikan performansi peralatan sesuai perancangan
Mengevaluasi semua komponen terhadap masalah yang
potensial menimbulkan kerusakan
Mengidentifikasi komponen yang dapat menyebabkan
kerusakan dan mengestimasi waktu sampai kerusakan
terjadi. Contoh: dinding pressure vessel mengalami
penipisan selama dioperasikan.
 PREVENTIVE MAINTENANCE
(TIME BASED)
Inspeksi dilakukan
Karena tuntutan peraturan: Pressure vessel harus
diinspeksi secara berkala sesuai dengan peraturan
pemerintah tentang keselamatan kerja.
Karena mesin tidak dilengkapi dengan cadangan dan
beresiko terhadap keberlangsungan proses produksi.
Pada peralatan yang sedang rusak
CORRECTIVE MAINTENANCE (PERBAIKAN) SEBAGAI
RESPONS TERHADAP INSPEKSI DALAM PM

Equipment availability

Biaya perbaikan
PREDICTIVE MAINTENANCE (PdM)

Preventive Maintenance

Time Based Condition Based

Maintenance Maintenance
 Predictive Maintenance
Predictive maintenance allows management to control
the machinery and maintenance programs rather than
vice versa. In a plant using predictive maintenance, the
overall machinery condition at any time is known, and
much more accurate planning is possible.
Benefits of Predictive Maintenance
The major benefit of predictive maintenance of
mechanical equipment is increased readiness due to
greater reliability of the equipment. The trending over
time of developing faults in machines can be carefully
done so as to plan maintenance operations to
coincide with scheduled shutdowns.
 SAAT PERAWATAN YANG TEPAT
Predictive Maintenance (PdM).
Perbaikan tepat pada waktunya

Perbaikan dilakukan Mesin terlambat

terlalu awal diperbaiki

Time based preventive maintenance (PM)

Predictive Maintenance Technologies

Lubrication analysis
Vibration analysis
Infrared thermography
Partial discharge (for generators, transformers
etc)
MCSA (Motor Current Signature Analysis) for
electric motors
Operating parameters (temperature, pressure,
flow rate etc)
Ultrasonic Acoustic
Smell, looking, feel, listen
 PROACTIVE MAINTENANCE
(PREVENTION MAINTENANCE)
Kerusakan premature (belum saatnya) dapat
terjadi atas peralatan
Mencegah perbaikan berulang atas kerusakan
premature
Kerusakan jenis tersebut harus dicari
penyebabnya dengan Root Cause Analysis
(RCA)
Improvement/redesign komponen dilakukan
berdasar hasil RCA
 Proactive Maintenance
Technologies
Dynamic Balancing
Precision Shaft Alignment
Ultrasonic Testing / Air & Steam
Belt / Pulley Alignment
Acceptance Testing
Water / Air Flow balancing & Measuring
Metering
 Pro-active Maintenance

Pro-active maintenance, which uses a variety of

technologies to extend the operating lives of
machines and to virtually eliminate reactive
maintenance. The major part of a pro-active
program is root cause failure analysis (RCA),
which is the determination of the mechanisms
and causes of machine faults. The fundamental
causes of machine failures can thus be
corrected, and the failure mechanisms can be
gradually engineered out of each machinery
installation.
 Maintenance Strategy Comparation

Maintenance Technique Needed Human Health Parallel

Strategy
Proactive Monitoring and Cholesterol and blood
correction of failing root pressure monitoring,
causes followed by diet control
Predictive Monitoring of vibration, Detection of heart disease
temperature, alignment, by ECG or ultrasonic
pressure, wear debris
Preventive Periodic components By-pass or transplant
replacement surgery

Break down Large maintenance Heart attack or stroke

budget
RCM (Reliability Centered Maintenance)
 RCM (Reliability Centered Maintenance)
RCM (Reliability Centered Maintenance)

Reactive, PM, Time PdM, Condition Proactive

RTF Based Based, Predictive

Small items Subject to wear out Random failure patterns Age exploration
Non critical Consumable Not subject to wear RCFA
replacement
Inconsequential PM Induced failures FMEA
Failure pattern known
Unlikely to fail Acceptance testing
Redundant

RCFA = Root Cause Failure Analysis

FMEA = Failure Mode and Effect Analysis
RCM (Reliability Centered Maintenance)
 RULES FOR BREAKDOWN
MAINTENANCE
If equipment is redundant
Low cost spares available
Interruptible process, stock pile
Safe failure modes
Long MTTF/MTBF
Low cost secondary damage
Quick repair/replacement (low cost of interuption
of production)
 RULES FOR PREVENTIVE
MAINTENANCE
Statistical failure rate available
Narrow failure distribution (predictable MTBF)
Maintenance restore full integrity
Single failure mode (known)
Low cost of regular overhaul/replacement
Unexpected interruption to production is
expensive (scheduled interruption is not so bad)
Low cost spares available
Reduced number of breakdown is required
Costly secondary damage
RULES FOR PREDICTIVE MAINTENANCE

Expensive/critical machinery
Long lead time for replacement (no spares)
Uninterruptible process (both regular and unexpected)-
costly
Large/complex machinery
Overhaul expensive (need highly trained people)
Reduced number of highly skilled maintenance people
Cost of monitoring program is acceptable
Safety is priority (failure dangerous)
Remote/mobile equipment
Failure is not indicated by operation degeneration
Costly secondary damage
 ALIRAN INFORMASI
Dari mana pekerjaan perawatan bermula?
Internal (dari dalam department of
maintenance): tugas preventive
maintenance dan corrective maintenance
Eksternal (dari luar departemen):
permintaan dari manajer produksi,
rehabilitasi
Komponen Penting dalam
Perawatan
Gunung Es Perawatan
Organisasi Perawatan