Maintenance Concept PAMA

(1)

MAINTENANCE

01

01 Modu

Modu

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Ma

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concept

P

(2)

MAINTENANCE

02

02 Modu

Modu

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Ma

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concept

Corrective/Unpla

Corrective/Unplanned nned Maint.Maint. •

•Tidak ada program maintTidak ada program maint •

•Operasikan sampai rusak, baruOperasikan sampai rusak, baru

lakukan perbaikan

Preventive Maint.

Preventive Maint. •

• Maint. Periodic terjadwalMaint. Periodic terjadwal •

• Replace/rebuild secara periodicReplace/rebuild secara periodic

sesuai standar umur

Predictive Maint.

Predictive Maint. •

•Condition-based maint.Condition-based maint. •

•Deteksi gejala kerusakanDeteksi gejala kerusakan •

•Prediksi kapan akan rusakPrediksi kapan akan rusak •

•Jadwalkan perbaikan sbl rusakJadwalkan perbaikan sbl rusak

1st Generation

2nd Generation

3rd Generation

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D

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(3)

MAINTENANCE

03 Module

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Main concept

CORRECTIVE MAINTENANCE

Failed Operate Repair

• Siklus

A nda tidak perlu melakukan apapun

s ampai terjadi kerus akan, kemudian

perbaiki !

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

(4)

MAINTENANCE

04 Module

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Main concept

PREVENTIVE MAINTENANCE

Periodic maintenance Operate

• Siklus

Periodic maintenance Operate

G anti komponen mes in Anda

s ecara periodic s es uai s tandar

umurnya, tidak peduli komponen

itu mas ih bis a diperpanjang

umurnya atau tidak !

LOW RISK

•Kepastian aktivitas maint. Tinggi •Unscheduled breakdown turun

Run Periodic

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

(5)

MAINTENANCE

05 Module

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Main concept

PREDICTIVE MAINTENANCE

Condition Monitoring Operate Scheduled repair Operate

• Siklus

_{Monitor terus kondisi mesin Anda setiap waktu,}

jika muncul gejala kerusakan, perbaiki sebelum jatuh rusak !

Perpanjang umur komponen mesin Anda jika Trend Performance-nya masih baik !

INCREASED COMPONENT LIFE EXPECTATION

Minor problem diperbaiki lebih dini

Data history memperkuat pembelian equipment Down time selalu terjaga minimum

Wow …. ini

biangnya !

(6)

MAINTENANCE

06 Module

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Main concept

PAMA MAINTENANCE CONCEPT

M a i n t e n a n c e P r o c e s s e s M a i n t e n a n c e V i s i o n

High Availability with Reliable Cost

Correcting failure

Preventing failure

Good Cleaning of Machines

Good Maintenance Management

(7)

MAINTENANCE

07 Module

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Main concept

PAMA MAINTENANCE PROCESSES

P2H - Pre use

check

Periodical

Service

Cleaning of

Machines

Service

Programs :

PPM, PPU,

PAP, PPB

Maintenance

Management

Component

Overhaul

Midlife

Maintenance

Processes

(8)

MAINTENANCE

08 Module

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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

B ers ihk an equipment A nda s ebelum

s cheduled maintenance !

B uatlah jadwal pencucian untuk

equipment A nda

!

(9)

MAINTENANCE

09 Module

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Main concept

P2H = PROGRAM PEMERIKSAAN HARIAN

Pre Use Check oleh Operator

• Menjamin bahwa mesin benar-benar siap operasi

• Mengetahui ketidaknormalan mesin lebih dini

• Mengetahui user’s opinion tentang kondisi

mesin

G unakan segala s umber untuk

memperoleh informas i kondis i

equipment A nda !

Li batkan peng g una equipment

A nda dalam maintenance

bus ines s !

Cek brake Cek ban /

undercarriage Cek panel

cabin Cek ASO air solar oli Cek battery Inspect kondisi umum Cek kebocoran Cek udara bertekanan

(10)

MAINTENANCE

10 Module

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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

Change corrossion resistor Greasing Change filter Change oil Change water coolant

Change air cleaner Scheduled

backlog repair

General check & adjustment

(11)

MAINTENANCE

11 Module

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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 Compressor Midlife Starting Motor Midlife Alternator Midlife Turbocharge Midlife

(12)

MAINTENANCE

12 Module

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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 Hydraulic

cylinder Ovh Electric_Wire Ovh Engine Ovh Transmission/PTO Ovh Pumps Ovh Final Drive Ovh undercarriage

(13)

MAINTENANCE

13 Module

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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 transmission/ Inspect noise

Test & adjust engine performance

Test & adjust hydraulic performance

Test & adjust pump performance

Inspect thermally Inspect visually,

detect crack

Test & adjust electric

•Compile data pengukuran •Analisa trend problem dan performance •Prediksi lifetime • Schedule-kan perbaikan

(14)

MAINTENANCE

Module

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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.

Ukur keausan teeht sprocket Ukur keausan rollers Adjust track tension Ukur keausan link

Ukur keausan pin & bushing link

Ukur keausan shoe grouser

Check modus keausan

Cek comp. free movement • Compile data pengukuran • Analisa trend keausan • Prediksi lifetime • Schedule-kan perbaikan

14

(15)

MAINTENANCE

15 Module

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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.

(16)

MAINTENANCE

Module

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Main concept

VISCOSITAS

WEAR METAL

16

I R O N ( F e ) 0 20 40 60 80 4931 9984 9757 10250 0 0 0 0 Ho u r M e t e r P p m Iron :

Sumber keausan : Piston, ring, cylinder, gear, block, head, cam, roller bearing, race.

Molybdenum :

Ring plating, alloy ( juga oil additive, off shelf supplement )

Chrome :

Various plating, liner, ring, some shaft gears.

Aluminum :

Piston, bushing, thrust, block, blower, cooler cores

Apa yg menyebabkan Viscosity berubah ?

Viscosity naik : - Oil teroksidasi

- Foaming/Pump Cavitation - Emulsi dengan air

- Jelaga atau kontaminasi padat

Viscosity turun :

- Fuel or kontaminasi terlarut - Refrigerant

(17)

MAINTENANCE

Module

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Main concept

• Maintenance Planning &

Improvement Setup

MAINTENANCE MANAGEMENT

• Maintenance Organization & Information

Setup

Workgroup Mechanics Group Leader Workgroup Mechanics Group Leader Supervisor Maintenance Planner Plant Dept. Head

• Parts process • Maintenance Schedule Machine’s hourmeter • Average Working Hour

Data Calculate & Process it !

17

• Maintenance Support Setup (Part, Komponen, Tool, Facility)

– Inventory

(18)

MAINTENANCE

Module

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Main concept

Optimum

AVAILABILITY

Reliable

COST

C o s t

Life hours

Optimum Point

Setup target maintenance yang

balance antara

A vailability

required

dengan

C os t s pent !

C o s t

Life hours

Rebuild Rebuild SCRAP ! 1st 2n d 3rd, …dst

18

(19)

MAINTENANCE

Module

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Main concept

MIMS = The Maintenance Information Management Tool

MIMS process average working hours Machine operation Input opr. hours MIMS process maintenanc e schedule MIMS process maintenanc e work order

MIMS Processing machine history :

•Failure history •Repair/Maintenance hystory •Component Tracing •R/M duration •R/M manhours •R/M Costing •Oil/fuel consumption MIMS process APL order

Data support for improvement

program Data support for

MIMS process part purchase Maintenance execution MIMS

19

(20)

MAINTENANCE

Module

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Main concept

IMPROVEMENT PROGRAM

• Pit Stop Servicing

- Fuel service, Greasing & oil service, Routine check service at pit stop station - Purpose : Reduce idle time

HYD OIL

ENGINE OIL

20

• 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