Has been defended before the examination committee in partial fulfillment of the requirement for a bachelor's degree in the industrial engineering department of Universitas Islam. Al-hamdu lillahi rabbil 'alamin and Gratitude is presented to Allah the Most High, Glory to Allah Infinite, the Exalted, who gave me the primary inspiration and perseverance all the time to complete this thesis acquiring the degree of Sarjana Technique, entitled "Maintenance Task Determination of Motor Dumper Component Using Reliability Centered Maintenance (RCM) and Fuzzy-FMEA Method". My family of Industrial Engineering International Program 2016 who have struggled together throughout the journey in Universitas Islam Indonesia.
The condition of the dump truck is important to maintain to prevent any traffic accidents during delivery. It is important to determine a proper maintenance task to prevent any engine component failure. Therefore, this paper aims to find the proposed maintenance task to eliminate or minimize engine failure.
Finally, the type of maintenance is determined according to the classification by Pareto and LTA, and the maintenance task is determined. While the maintenance task depends on the type of maintenance; preventive maintenance and predictive testing and inspections.
- Problem Formulation
- Research Objectives
- Research Limitation
- Research Benefits
- Systematical Writing
Sea transport, for example barge, is used to distribute coal from the coal producers to Java Island, which is anchored in the port. While land transport is used to distribute coal from the port directly to the industries that separated in many cities on the island of Java. The coal from Cirebon Port is distributed to industries located in West Java, for example Bandung, Purwokerto, etc.
To distribute coal from Cirebon Port, there are private distribution companies that get a contract with the coal supplier. The distribution mechanism starts from the company getting a contract with the coal supplier to distribute a certain amount of coal that is adapted to the dumper's capacity. Darma Titipan is a distribution company involved in the coal distribution from Cirebon Port to industries in West Java.
This type of maintenance usually does not allow the company to prevent the accident because some part of the truck breaks down while distributing the coal to the industries. When the accident happened, it caused a great loss to the company, such as the loss of damage to the truck, the coal compensation to the coal supplier, etc.
Inductive Study
The Hazard Priority Number (RPN) is one of the main factors in determining the criticality ranking of a mechanical device failure mode. The FMEA results show that the critical system components are the gearbox pump drive and the oil cycle. The FRPN value is obtained by generating the Fuzzy field taking into account the degree of importance of the given input data.
In order to achieve a risk prioritization that better reflects customer perception regarding dissatisfaction, a fuzzy calculation of RPN was proposed. In this work, information is provided on the steps and procedures to identify critical components of ISM using failure modes and effects analysis (FMEA). Application of the reliability-centered maintenance methodology showed that the maximum time between failures of the plant's equipment and the probability of sudden equipment failures are reduced.
The proposed PM scheduling results show a saving of about 80% of the total downtime cost compared to that of actual maintenance. Most researchers conclude that the use of Fuzzy-FMEA is more suitable to be applied in risk assessment.
Deductive Study
Research Subject
Research Object
Data Types
Research Flow
Data Collecting
- Company Profile
- Business Process
- Maintenance Process
- FMEA
- Fuzzy Logic
The distribution process starts from the company's demand contract to the coal supplier. The company delivers the rejected coal to the coal supplier and the coal distribution process is repeated. This research will focus on the maintenance of the dump truck and especially on the truck's engine.
Darma Titipan is started by checking the engine condition before the dump truck distributed coal to industry. In the journey of the distribution of coal, if there is a fault on the engine, the truck must stop the journey and wait for the engineer of the company to fix the engine. While the engine condition is good, the truck will complete the journey to the intended operation.
From the explanation, the form of maintenance is corrective maintenance because the maintenance process is carried out after there is a fault on the engine. According to Akhmad & Taufik (2010), the function of each engine component is explained in Table 4.1 below. Cylinder head Cover the top of the engine block and as a housing for the valve mechanism.
The code mentioned in Table 4.2 is suggested in order to facilitate writing in the next step. Each effect has its own severity which represents its rate of danger to the engine system. In this part, the potential cause of the failure will be identified to know the occurrence of the causes which will be presented as follows in Table 4.4.
In this case, the check made by the company is to measure whether the engine component can still work or not. The selection of the fuzzy set is based on the reference from the journal by Filo, et al (2018) which divided the crisp value into five fuzzy sets. The selection of the fuzzy set is based on the journal reference by Filo, et al (2018), which is explained in Table 4.7.
Data Processing
- Fuzzy-FMEA
- Logic Tree Analysis
- Maintenance Strategy
Based on the maintenance decision tree, the maintenance strategy is divided into three categories: preventive maintenance, predictive testing and inspection maintenance, and reactive maintenance. The preventive maintenance maintenance task is performed by determining the maintenance interval of the component. While in predictive test maintenance, the maintenance task is determined by checking the symptoms of the component failure.
In this category, the maintenance task is performed by determining the maintenance interval for the component. There are several steps to determine the maintenance interval, which will be described as follows. Therefore, the routine maintenance will not be effective in preventing the failure of the round bearing.
The knocking sound or "tuk tuk" from the engine indicates the failure of the main bearing. Repair of the component is carried out when the fault can be dealt with and it does not cause a large effect on the performance of the engine. From the maintenance decision tree, it was found that there are 5 failure modes with time-based maintenance, 10 failure modes use condition-based maintenance, and 2 failure modes use corrective maintenance.
For preventive maintenance, the maintenance task depends on the maintenance interval time determined by the calculation of the reliability value. Therefore, the maintenance task suitable for a circular bearing is to replace a part before the maintenance interval and prepare the replaced part. However, if the company replaces the bearing within the specified replacement time, the maintenance time will be one day for replacement.
In this research, the maintenance task for predictive testing and inspection focused on the high classification. For main bearing, the maintenance is by checking the sound of the engine when the truck is in the steady state. Based on the discussion, it can be concluded that the maintenance tasks depend on the type of maintenance type used for component; preventive maintenance and predictive testing and inspection.
For preventive maintenance, the maintenance task of the spherical bearing as the highest value of F-RPN is to prepare the component and replace the component in the 18th month after the previous replacement. For predictive testing and inspection, maintenance is performed by checking for symptoms of failure in each component.
