MANAJEMEN

PERAWATAN ALAT
BERAT
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Predictive Maint.
Condition-based maint.
Deteksi gejala kerusakan
Prediksi kapan akan rusak
Jadwalkan perbaikan sbl rusak

3rd Generation
Preventive Maint.
Maint. Periodic terjadwal
Replace/rebuild secara periodic
sesuai standar umur

2nd Generation
Corrective/Unplanned Maint.
Tidak ada program maint
Operasikan sampai rusak, baru Dimanakah kita sekarang ?
lakukan perbaikan
apa misi jangka panjang kita ?
1st Generation
apakah kita mendapat vendor support ?
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CORRECTIVE MAINTENANCE

Siklus
Operate
Tidak perlu melakukan apapun sampai
Failed
terjadi kerusakan, kemudian perbaiki !

Repair

REACTIVE MAINTENANCE
Tak ada waktu utk menganalisa kerusakan
Perbaiki hanya jika rusak
Tak ada data untuk dipelajari
Semua aktivitas adalah UNSCHEDULED !

VERY HIGH MAINTENANCE COST

Lembur
Loss production
Inventory tinggi
Resiko tinggi

SHORT COMPONENT LIFE

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PREVENTIVE MAINTENANCE

Siklus
Operate Ganti komponen mesin Anda
Periodic
maintenance secara periodic sesuai standar
umurnya, tidak peduli komponen
itu masih bisa diperpanjang
Periodic umurnya atau tidak !
Operate maintenance
LOW RISK
Buat jadwal
Kepastian aktivitas maint. Tinggi
Unscheduled breakdown turun
perbaikan !

MODERATELY HIGH MAINT. COST

Waktu dan biaya kurang efisien
Production loss dari unscheduled downtime masih ada

SHORT COMPONENT LIFE

Tak ada upaya perpanjangan umur komponen
Tak ada analisa akar masalah
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PREDICTIVE MAINTENANCE

Siklus Monitor terus kondisi mesin Anda setiap waktu,

Operate jika muncul gejala kerusakan, perbaiki sebelum
Condition
Monitoring jatuh rusak !
Perpanjang umur komponen mesin Anda jika
Trend Performance-nya masih baik !

Operate Scheduled
Trend Analyses
repair

INCREASED COMPONENT LIFE

EXPECTATION
Minor problem diperbaiki lebih dini
Data history memperkuat pembelian equipment
Down time selalu terjaga minimum
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MAINTENANCE CONCEPT
Maintenance

High Availability with Reliable Cost

Vision
Maintenance

Preventing failure Correcting failure

Processes

Predicting failure

Good Cleaning of Machines

Good Maintenance Management
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PROSES MAINTENANCE

Cleaning of P2H - Pre use

Machines check

Maintenance
Management Periodical
Maintenance Service
Processes

Service
Programs :
Component PPM, PPU,
Overhaul PAP, PPB

Midlife
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CLEANING OF MACHINES

Kebersihan adalah dasar bagi repair & maintenance quality.

Menghindari kerusakan akibat kotoran, lumpur, debu, dan kontaminasi bahan mudah terbakar.
Meningkatkan ketajaman inspeksi
Meningkatkan kenyamanan kerja maintenance
Meningkatkan kenyamanan operasi

Bersihkan peralatan Anda sebelum

scheduled maintenance !
Buatlah jadwal pencucian untuk
equipment Anda !
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INSPEKSI HARIAN

Pre Use Check oleh Operator

Menjamin bahwa mesin siap operasi Gunakan segala sumber untuk
memperoleh informasi kondisi
Mengetahui ketidaknormalan mesin lebih dini
equipment!
Mengetahui kondisi mesin menurut pengguna
Libatkan Operator!

Cek panel
cabin Cek

Inspect kondisi
Cek udara umum
bertekanan

Cek battery

Cek kebocoran
Cek ban /
undercarriage Cek brake
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PERIODIC SERVICE
Maintenance rutin dengan dasar interval 250 , 500 , 750 , 1000 , 2000 , 6000 operating hours

Mencegah breakdown unscheduled akibat penurunan normal performance oil dan parts

Mendeteksi kerusakan lebih dini

Scheduled
backlog repair Change oil

Greasing

Change filter

General check & Change corrossion

adjustment resistor

Change water Change air cleaner

coolant
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MIDLIFE

Rebuild/replacement rutin atas komponen kecil / asesoris dengan dasar setengah standar
umur komponen besar (6000 7000 operating hrs )

Mencegah breakdown unscheduled akibat penurunan normal performance komponen kecil.

Midlife Alternator

Midlife Starting Midlife Compressor

Motor

Midlife
Turbocharge

Midlife
Midlife nozzle Waterpump
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COMPONENT OVERHAUL
Rebuild/replacement komponen besar secara rutin berdasarkan life time
komponen.
Engine 14000 hrs
Transmission 12000 hrs
Differential 14000 hrs, dst

Mencegah unscheduled breakdown akibat penurunan normal performance komponen

besar.
Ovh
Ovh Engine Transmission/PTO

Ovh Pumps

Ovh Hydraulic Ovh Electric

cylinder Wire

Ovh Ovh Final

undercarriage Drive
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PROGRAM PEMERIKSAAN UNIT ALAT BERAT

Machine Condition Monitoring

Inspeksi, pengukuran, dan adjustment mesin secara rutin
berdasarkan interval 1000 operating hours
Memprediksi gejala kerusakan, memprediksi umur tersisa,
menyusun jadwal perbaikan.

Test & adjust Test & adjust

engine hydraulic performance
Compile data
performance pengukuran
Test & adjust
Inspect noise
pump performance Analisa trend
problem dan
performance
Inspect visually,
Inspect thermally
detect crack Prediksi lifetime
Schedule-kan
Test & adjust perbaikan
Test & adjust electric
performance transmission/ PTO
performance
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PEMERIKSAAN UNDERCARRIAGE

Undercarriage Condition Monitoring

Inspeksi, pengukuran, dan adjustment komponen undercarriage secara rutin berdasarkan interval 500
opr hrs (high travel crawler) atau 2000 opr hrs (low travel crawler)
Memprediksi gejala kerusakan, memprediksi
umur tersisa, menyusun jadwal perbaikan.

Adjust track Ukur

tension keausan link

Ukur keausan Ukur keausan pin

Compile data
teeht sprocket & bushing link
pengukuran
Analisa trend
Ukur keausan Ukur keausan keausan
rollers shoe grouser
Prediksi lifetime

Check modus Cek comp. free Schedule-kan

keausan movement perbaikan
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ANALISA PELUMAS

Oil Lub Condition Monitoring

- Wear metal analyses
- Contamination analyses (metal, water, fuel, dirt)
- Additive deterioration analyses
- Viscosity
- Fuel soot GEAR
OIL

ENGINE OIL
Oil lub condition analyses secara rutin berdasarkan interval :
- 250 opr hrs (engine oil)
- 1000 opr hrs (hydraulic oil, gear oil)

Memprediksi gejala kerusakan, memprediksi umur tersisa, menyusun

jadwal perbaikan.
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IR ON ( F e)
80

60

Ppm
40

20

0
4931 9984 9757 10250 0 0 0 0
Ho ur M et er

WEAR METAL VISCOSITAS

Iron : Apa yg menyebabkan Viscosity berubah ?

Sumber keausan : Piston, ring, cylinder, gear, block,
head, cam, roller bearing, race. Viscosity naik :
- Oil teroksidasi
Chrome : - Foaming/Pump Cavitation
Various plating, liner, ring, some shaft gears. - Emulsi dengan air
- Jelaga atau kontaminasi padat
Molybdenum :
Ring plating, alloy ( juga oil additive, off shelf Viscosity turun :
supplement )
- Fuel or kontaminasi terlarut
Aluminum : - Refrigerant
Piston, bushing, thrust, block, blower, cooler cores - Salah pengisian atau penambahan oil
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MAINTENANCE MANAGEMENT
Maintenance Planning &
Maintenance Organization & Information Improvement Setup
Setup
Machines
Plant Dept. Head hourmeter

Supervisor Maintenance
Planner Data Calculate & Process it !

Group Leader Group Leader

Workgroup Workgroup
Mechanics Mechanics
Average
Working Hour

Maintenance Support Setup (Part, Komponen, Maintenance

Tool, Facility) Schedule
Inventory Parts
Vendor/Consignment Support process
Tools & Facility investment Manhour
calculation
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Setup target maintenance yang

balance antara Availability
Optimum Reliable required dengan Cost spent !
AVAILABILITY COST

Cost
Rebuild
Cost
Optimum
Point Rebuild SCRAP !

1st 2n 3rd, dst

d
Life hours Life hours
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MIMS = The Maintenance Information Management Tool

MIMS
process MIMS
maintenanc process
Machine e work part
operation order purchase
MIMS MIMS Maintenance
Input opr. process process execution
hours maintenanc APL order
e schedule MIMS
MIMS
process MIMS Processing machine history :
average Failure history
working
Repair/Maintenance hystory
hours
Component Tracing
Data support for R/M duration
improvement R/M manhours
program
R/M Costing
Oil/fuel consumption
Data support for
effective decision Availability, MTBF, etc
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Terima kasih