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MAINTENANCE 01 Module Main concept

PAMA MAINTENANCE CONCEPT

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 02 Module Main concept

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 ?

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 03 Module Main concept
CORRECTIVE MAINTENANCE

Siklus
Operate
Anda tidak perlu melakukan apapun
Failed
sampai 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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 04 Module Main concept
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
Run Periodic
Kepastian aktivitas maint. Tinggi
Unscheduled breakdown turun
Maint. Schedule !

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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 05 Module Main concept
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

Wow . ini
biangnya !
INCREASED COMPONENT LIFE
EXPECTATION
Minor problem diperbaiki lebih dini
Data history memperkuat pembelian equipment
Down time selalu terjaga minimum

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 06 Module Main concept
PAMA MAINTENANCE CONCEPT
Maintenance

High Availability with Reliable Cost


Vision
Maintenance

Preventing failure Correcting failure


Processes

Predicting failure

Good Cleaning of Machines


Good Maintenance Management

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 07 Module Main concept
PAMA MAINTENANCE PROCESSES

Cleaning of P2H - Pre use


Machines check

Maintenance
Management Periodical
Maintenance Service
Processes

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

Midlife

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 08 Module Main concept
CLEANING OF MACHINES

Kebersihan mesin 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 equipment Anda sebelum


scheduled maintenance !
Buatlah jadwal pencucian untuk
equipment Anda !

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 09 Module Main concept
P2H = PROGRAM PEMERIKSAAN HARIAN

Pre Use Check oleh Operator


Menjamin bahwa mesin benar-benar siap Gunakan segala sumber untuk
operasi memperoleh informasi kondisi
equipment Anda !
Mengetahui ketidaknormalan mesin lebih dini
Libatkan pengguna equipment
Mengetahui users opinion tentang kondisi Anda dalam maintenance
mesin Cek panel business !
cabin Cek ASO air
solar oli

Inspect kondisi
Cek udara umum
bertekanan

Cek battery

Cek kebocoran
Cek ban /
undercarriage Cek brake

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 10 Module Main concept
PERIODICAL 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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 11 Module Main concept
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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 12 Module Main concept
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


Ovh penurunan normal performance komponen
besar. Ovh Engine Transmission/PTO

Ovh Pumps

Ovh Hydraulic Ovh Electric


cylinder Wire

Ovh Ovh Final


undercarriage Drive

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 13 Module Main concept
PPM = PROGRAM PEMERIKSAAN MESIN

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 engine Test & adjust hydraulic


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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 14 Module Main concept
PPU = PROGRAM 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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 15 Module Main concept
PAP = PROGRAM 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.

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 16 Module Main concept
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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 17 Module Main concept
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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 18 Module Main concept

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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 19 Module Main concept
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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 20 Module Main concept
IMPROVEMENT PROGRAM
Pit Stop Servicing
- Fuel service, Greasing & oil service, Routine check service at pit stop station
- Purpose : Reduce idle time

Backlog Management
- Potential failure execution during periodic service time
- Purpose : Reduce unscheduled breakdown

Oil life and component life extend


- Supported with oil filtering improvement, PAP& PPM condition monitoring
- Purpose : Reduce material cost, man hour, and downtime
HYD
OIL

Modification ENGINE OIL

- Larger coal bucket, coal vessel, fuel tank


- Auto lube , etc.

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT


MAINTENANCE 21 Module Main concept

Terima kasih

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT