MAINTENANCE 01 Module – Main concept

SIS BIRO MAINTENANCE CONCEPT

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT

MAINTENANCE 02 Module – Main concept
Y
R Predictive Maint.
O
T • Condition-based maint.
IS • Deteksi gejala kerusakan
H • Prediksi kapan akan rusak
E • Jadwalkan perbaikan sbl rusak
C
N
A 3rd Generation
N
E
T Preventive Maint.
IN • Maint. Periodic terjadwal
A
M • 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

SCHEDULE
MAINT.
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
SIS BIRO MAINTENANCE CONCEPT
Maintenanc
e Vision

High Availability with Reliable Cost

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
SIS BIRO MAINTENANCE PROCESSES

Cleaning of P2H - Pre use

Machines check

Maintenance
Management Periodical
Maintenance Service
Processes

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

Midlife
r i ght !
Do i t

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 operasi Gunakan segala sumber untuk
• Mengetahui ketidaknormalan mesin lebih dini memperoleh informasi kondisi
equipment Anda !
• Mengetahui user’s opinion tentang kondisi mesin
Libatkan pengguna equipment
Anda dalam maintenance
Cek panel business !
cabin Cek
Inspect kondisi
umum

Cek udara
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 , 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
Turbocharger

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 penurunan normal performance komponen besar.

Ovh Engine Ovh

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 • Analisa trend
performance
problem dan
performance
Inspect visually,
Inspect thermally
detect crack • Prediksi lifetime
• Schedule-kan
Test & adjust electric Test & adjust transmission/ perbaikan
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 O N ( F e )
80

60

Ppm
40

20

0
4931 9984 9757 10250 0 0 0 0
Ho ur M e t e r

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 Setup Improvement Setup

Machine’s
P lan t D ep t. H ead hourmeter

S u p e rvis or M ain ten an c e

P lan n e r Data Calculate & Process it !

G rou p L ea d e r G rou p L ea d e r MIMS

W o rk g rou p W o rk g ro u p
M ec h an ic s M ec h an ic s • 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

Rebuild

Cost
Availability
Optimum
Cost
Availability

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

PT. PAMAPERSADA NUSANTARA MECHANIC DEVELOPMENT