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Maintainability,

Realability dan Quality


Oleh : M. Abdito, Teuku Gaisha A dan Tommy Novianto
Maintainability,
Maintainability References
Systems Engineering and Analysis
Benjamin S. Blanchard and Walter J. Fabrycky
Prentice Hall, 3rd edition 1998, ISBN 0-13-135047-1

Maintainability Principles and Practices
Benjamin S. Blanchard and E. Edward Lowery
McGraw-Hill

MIL-STD-470 Maintainability Programs for Systems and Equipment
MIL-STD-471 Maintainability Verification / Demonstration / Evaluation
MIL-HDBK-472 Maintainability Prediction

Objective of Maintainability
Design and develop systems/equipment which can be maintained
in the least time, at the least cost, and with a minimum expenditure of
support resources, without adversely affecting the item performance or
safety characteristics

Maintainability greatly influences reliability and availability of a system or
subsystem.

Maintainability must be addressed early in the design stage to prevent or reduce
failure or down times of the system.

Maintenance and Design
1) The systems design determines its requirements for maintenance
Reliability (How often maintenance)
Configuration (How much time for access)
Built in Test (Fault Isolation Time)
Subassembly life span (Inspection/forced replacement)
Adjustment/alignment requirements (Inspection)
Capacity/fill rate (Servicing)
Corrosion susceptibility (Inspection/repair)

Maintainability Definitions
Maintainability is an inherent design characteristic of a system or product and
it pertains to the ease, accuracy, safety, and economy in the performance of
maintenance actions.

Maintainability is the probability that a failed system will be restored to
specified performance within a stated period of time when maintained under
specified conditions
Maintainability Metrics
Times
MTTR : Mean Time to Repair
T
5o%
: Median Time to Repair
T
MAX
: Maximum Time to Repair
(usually 95
th
percentile
LDT : Logistics Delay Time
SDT : Supply Delay Time
MDT : Mean Down Time
DTM : Down Time for Maintenance
DTS : Down Time For Supply
Events
MTBM : Mean Time Between Maintenance
MTTPM : Mean Time to Preventive Maintenance
MTBPM : Mean Time Between Preventive Maintenance
Manpower
CS : Crew Size
MMH/FH : Man-hours per flight hour
Diagnostics
FD : Fault Detection
FI : Fault Isolation
FA : False Alarms

Total
Time
Inactive
Time
Active
Time
Up
Time
Not Operating
Time
Alert
Time
Inactive
Time
Down
Time
Maintenance
Time
Modification
Time
Delay
Time
Corrective
Maintenance
Time
Preventive
Maintenance
Time
Supply
Delay
Time
Administrative
Delay
Time
System Time Relationships
Maintenance Categories
Maintenance
Preventive Maintenance
(retain item functionality)
Corrective Maintenance
(reestablish item functionality)
Test of all relevant
functions,
Inspect to detect hidden
failures
Service to replace
consumables
Activities to compensate for
drift and
to reduce wear out failures
Overhaul to increase useful
life
Time Change
Prognostics health
management: monitor and
repair before failure
Failure detection
Failure isolation
Repair
Functional test
Maintenance Definitions
Maintenance:
All actions necessary for retaining an item in, or restoring it to, a serviceable
condition
Includes servicing, repair, modification, overhaul, inspection, and condition
verification

Maintenance categories:
1. Preventive Maintenance
Maintenance performed to retain an item in satisfactory operational condition by providing system
inspection, detection and prevention of incipient failures, overhaul, lubrication, calibration, etc
Prescribe procedures to reduce the probability of failure or degradation

2. Corrective Maintenance
Initiated after fault detection
To Regain state of system for performing required function

Detection
Preparation for
Maintenance
Location and
Isolation
Disassembly
(Access)
Removal of
Fault Item
Re-assembly
Alignment
and Adjustment
Condition
Verification
or
Repair of
Equipment
Installation of
Spare/Repair Part
Failure Occurs
Failure Confirmed
Active Maintenance Commences
Faulty Item Identified
Disassembly Complete
Re-assembly Complete
Repair Completed
Corrective Maintenance Cycle

Realability
Reliability
Apakah reliability itu?
kehandalan

peluang sebuah komponen, sub-sistem atau sistem melakukan fungsinya
dengan baik, seperti yang dipersyaratkan, dalam kurun waktu tertentu dan
dalam kondisi operasi tertentu pula.


Reliability mengandung komponen peluang, maka secara
inheren didalamnya Ada masalah statistik, seperti:

1. Uncertainty
2. Probability
3. Probability Distributions

Namun paling sering berhubungan adalah dengan masalah
Probabilitas

Teori teori probabilitas banyak digunakan dalam hubungan
Reliability.

Karena mengandung komponen melakukan
fungsi dengan baik, maka didalamnya secara
inheren pula terdapat faktor kegagalan sistem.
Sebab peluang kegagalan dari sebuah mesin (misalnya)
adalah kebalikan dari peluang kehandalannya seperti
digambarkan dalam ekspresi matematik
(cumulative damage/failure distribution function) sbb :


Pf (t) = 1 R(t) atau R(t) = 1 Pf(t)


Jadi jika kehandalan sebuah mesin adalah R =90%,
maka peluang kegagalan cumulativenya adalah Pf = 10%,
atau sebaliknya.

TIME
Berhubungan dengan waktu, alat yang reliability tahun ini belum tentu reliability
tahun depan jika ada:
mekanisme kerusakan yang beroperasi (operative damage mechanism)
dengan laju kerusakan tertentu (misalnya laju korosi atau aus 0.01 mm/year).
Reliability Diagram
Risk
Berbicara reliabilty juga sama artinya dengan berbicara risk
(resiko), sebab risk didefiniskan sebagai :








Jadi salah satu komponen risk adalah kebalikan dari reliability
(Probability of Failure), oleh sebab itu jika bicara reliability
selalu dikaitkan dengan risk.
Reliability pada teknik mesin
Pada teknik mesin reliability dapat berarti melihat kehandalan sebuah mesin
(rotating machine) melakukan fungsinya tanpa mengalami kegagalan. biasanya
dikaitkan dengan konsep maintenance seperti MTBF (mean time between
failure), atau RCM (Reliability-centered Maintenance)
Quality
Standar
International organization of standardization (ISO)
ASME
SNI
IEEE
ITU


Pengertian
Kualitas menurut KBBI adalah tingkat baik buruknya sesuatu.
Atau kualitas berarti:
-Sesuai dengan spesifikasinya
-Tidak ada kecacatan
-Kepuasan pelanggan

Dimensi Kualitas meliputi:
Performance
Feature
Reliability
Conformance
Durability
Serviceability
Aesthetic
Perception
Biaya Kualitas
Control Cost
a. Pervention Cost
Planning, Review, training, Data, Improvemnt
b. Inspection Cost
Inspeksi, quality lab
Failure Cost
a. Internal Failure Cost
scrap, rework, retest, downtime
b. External Failure Cost
Warranty, returns, complaints


Metode Perancanaan Standar Kualitas
1. Quality Function Deployment (QFD)
+ Dapat memahami kebutuhan pelanggan & proses desain berasal dari
kebutuhan pelanggan yang objektif
+Mengutamakan kegiatan desain
+Mengurangi kegiatan perubahan desain
+Menyediakan dasar yang jelas untuk suatu keputusan desain
2. Metode Value Engineering
+berorientasi menambah nilai untuk produk atau jasa
+Mengurangi modal dan biaya siklus hidup
+Berusaha mencapai mutu yang minimal dengan biaya yang semurah mungkin

Metode Kualitas dalam Manajemen
Total Quality Management (TQM)
-Kepemimpinan & manajerial komitmen
-Kemauan tim
-Partisipasi suplier
-cost of quality
-training
-statistik
-pelayanan konsumen
Basic Steps of TQM
Create a vision -> Plan an action -> Create a structure -> Measure Progress ->
Update plans and vision as appropriate
Pertanyaan

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