TIRE SECTION AT LEADING TIRE MANUFACTURER
By
Muhammad Mushlih Fadlulloh 21952015
MASTER’S DEGREE in
MASTER OF MECHANICAL ENGINEERING – ENGINEERING MANAGEMENT
FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
February 2021
Revision after Thesis Defense on January 26, 2021
Muhammad Mushlih Fadlulloh STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Muhammad Mushlih Fadlulloh
____________________________________________
Student Date
Approved by:
Dr Eng. Aditya Tirta Pratama, S.Si, M.T.
____________________________________________
Thesis Advisor Date
Dr. Ir. Henry Nasution, M. T.
____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium, S. Kom., M. Sc.
____________________________________________
Dean
Date Revision after Thesis Defense on January 26, 2021
Muhammad Mushlih Fadlulloh ABSTRACT
ENHANCING MAINTENANCE MANAGEMENT SYSTEM USING RELIABILITY CENTERED MAINTENANCE (RCM) CASE STUDY CURING
TIRE SECTION AT LEADING TIRE MANUFACTURER
By
Muhammad Mushlih Fadlulloh
Dr Eng. Aditya Tirta Pratama, S.Si, M.T., Advisor Dr. Ir. Henry Nasution, M. T., Co-Advisor
SWISS GERMAN UNIVERSITY
PT MTI is a company that produces motorcycle tires. The company has the problem of not achieving the production of the target. The average production achievement is only 93.65%. The biggest cause is downtime curing machine, especially the M Closing Force Problem. The total loss due to downtime curing machine reaches to IDR 37,211,400,000.00 per year. Companies must improve maintenance program.
The method is the RCM concept by combining the FMEA and Seven tools, besides using financial analysis to find BEP. Based on the maintenance data, the reliability value can be obtained from the MTBF and MTTR. Obtained the greatest MTBF value is 1057 hours and MTTR of 4.62 and the value of reliability is 0.36803. The action in predictive maintenance is the replacement spare parts of the machine, such as the upper body, lower body, crank gear, arm and dial gauge. The preventive maintenance action is to replace the crank gear bushing every 3.5 months. The BEP improve is 9.65 month and the cost reduction is IDR 2,332,349,008.65 in the first year and IDR 8,518,599,008.65 in the second year.
Keywords: Reliability, Downtime, Maintenance Strategy, Tire Manufacturing, Break Even Point
Muhammad Mushlih Fadlulloh
© Copyright 2021
By Muhammad Mushlih Fadlulloh All rights reserved
Muhammad Mushlih Fadlulloh DEDICATION
This thesis is dedicated to the improvement of the company so that it can continue to compete in local and international markets.
Muhammad Mushlih Fadlulloh ACKNOWLEDGEMENTS
With His grace, Alhamdulillah, the author can complete this thesis on time. This thesis will not be completed without the help and support of various parties. The author would like to express my deepest gratitude to all those involved in writing this thesis, namely:
1. Amir Zainuddin and Nurmi Sri Herwati as the author's father and mother who always support and wish their children the success.
2. Nindya Septiliani and Asyraf Fadlan Zaahirulhaq as my family who always support to the author.
3. Dr. Ita Mariza, as the Director of the Gajah Tunggal Polytechnic who has fought for and facilitated writers to continue their education.
4. Dr. Ir. Gembong Baskoro, M.sc as SGU's Strategic Development and Cooperation Director who always provides motivation and education.
5. Dr. Eng. Aditya Tirta Pratama, S.Si, M.T as Advisor who always gives directions and corrections in writing his thesis.
6. Dr. Ir. Henry Nasution, M. T. as Co-Advisor who always gave directions and corrections in writing the thesis.
7. Dena Hendriana, B.Sc., S.M., Sc.D as Dean of the Faculty of Engineering and Information Technology at Swiss German University who has streamlined the thesis writing process.
8. Swiss German University student friends who always support and encourage each other from the beginning to the end of the lecture period
Muhammad Mushlih Fadlulloh Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENT ... 7
LIST OF FIGURES ... 9
LIST OF TABLES ... 10
1. CHAPTER 1 - INTRODUCTION ... 11
1.1. Background ... 11
1.2. Research Problems ... 15
1.3. Research Objectives ... 15
1.4. Significance of Study ... 15
1.5. Research Questions ... 16
1.6. Scope and Limitation ... 16
1.7. Thesis Structure ... 16
2. CHAPTER 2 – LITERATURE REVIEW ... 18
2.1. Maintenance ... 18
2.1.1. Definition of maintenance... 18
2.1.2. Maintenance function... 19
2.1.3. Maintenance purpose ... 19
2.1.4. Maintenance strategy ... 19
2.2. Reliability Centered Maintenance (RCM) ... 20
2.2.1. Purpose of reliability centered maintenance ... 21
2.3. Failure Mode and Effect Analysis (FMEA) ... 22
2.4. Reliability Availability Maintainability ... 25
2.4.1 Reliability ... 25
2.4.2 Availability ... 26
2.4.3 Maintainability ... 26
2.5. Curing Process ... 26
2.6. Financial Feasibility Analysis ... 28
2.6.1. Break even point (BEP) ... 28
2.6.2. Net present value (NPV) ... 28
2.6.3. Incremental rate of return (IRR) ... 29
2.6.4. Payback period (PP). ... 30
2.6.5. Return on investment (ROI)... 30
2.7. Exponential Distribution Function ... 31
3. CHAPTER III – RESEARCH METHODOLOGY ... 33
3.1. Research Flow ... 33
3.2. Object Research... 34
3.3. Research Framework ... 35
3.4. Data Sources and Collection ... 36
3.5. Method of Analysis ... 36
4. CHAPTER 4 – RESULT AND DISCUSSION ... 38
4.1. Data Collection ... 38
4.1.1. Production data performance ... 38
4.1.2. Downtime data ... 41
4.1.3. Part of curing machine BOM type ... 45
Muhammad Mushlih Fadlulloh
4.1.4. Existing condition ... 47
4.2. Data Analysis ... 48
4.2.1. Analysis production achievement and downtime using fishbone ... 48
4.2.2. MTBF and MTTR Data ... 49
4.2.3. FMEA analysis ... 50
4.3. Distribution Data Analysis ... 52
4.3.1. Remove outlier from MTBF and MTTR data ... 52
4.3.2. New MTBF and MTTR ... 53
4.3.3. Distribution analysis using SPSS and statfit promodel ... 55
4.3.4. Reliability, maintainability and availability ... 58
4.4. Improvement Maintenance Program ... 62
4.4.1. Predictive maintenance program ... 62
4.4.2. Cost of predictive maintenance ... 62
4.4.3. MTBF and MTTR Data After Improve ... 64
4.4.4. Reliability Data After Improve ... 65
4.4.5. Preventive maintenance program ... 66
4.4.6. Cost of preventive maintenance ... 67
4.4.7. Total cost of maintenance ... 67
4.5. Improvement Analysis ... 67
4.6. Improvement Progress... 69
5. CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 71
5.1. Conclusion ... 71
5.2. Recommendation ... 71
6. APPENDIX... 72
REFERENCE ... 83
CURRICULUM VITAE ... 86
Muhammad Mushlih Fadlulloh LIST OF FIGURES
Figures Page
Figure 1.1 Production capacity PT MTI ... 11
Figure 1.2 Product of PT MTI ... 12
Figure 1.3 Flow process tire manufacturing ... 12
Figure 1.4 Curing machine hydraulic and BOM type ... 14
Figure 2.1 Mind map research ... 18
Figure 2.2 Curing Process ... 27
Figure 2.3 Part of Curing Machine ... 27
Figure 3.1 Research flow ... 34
Figure 3.2 Curing machine ... 34
Figure 3.3 Flow process curing tire ... 35
Figure 3.4 Research framework ... 36
Figure 4.1 Production achievement ... 38
Figure 4.2 Analysis lost production ... 39
Figure 4.3 Production data 2020 ... 39
Figure 4.4 Lost of analysis production 2020 ... 40
Figure 4.5 Pareto of production problem ... 41
Figure 4.6 Caused Of M Closing Force Problem ... 44
Figure 4.7 Part of curing machine BOM type... 45
Figure 4.8 Part of curing machine BOM type continue ... 45
Figure 4.9 Part of curing machine BOM type continue ... 46
Figure 4.10 Existing condition curing machine BOM type ... 47
Figure 4.11 Fishbone production not achievement from KPI... 48
Figure 4.12 Fishbone downtime curing machine ... 48
Figure 4.13 Find outlier data TBF adjuster ... 52
Figure 4.14 Find outlier data TTR adjuster ... 53
Figure 4.15 Statfit adjuster data ... 55
Figure 4.16 Goodness of fit adjuster data ... 56
Figure 4.17 Statfit crank gear data ... 56
Figure 4.18 Goodness of fit crank gear data ... 57
Figure 4.19 Curing machine after improve ... 63
Figure 4.20 Upper and lower body ... 63
Figure 4.21 Arm crank gear and dial gauge after improve ... 64
Figure 4.22 Percentage improvement progress ... 70
Muhammad Mushlih Fadlulloh LIST OF TABLES
Table Page
Table 2.1 Severity value ranking ... 23
Table 2.2 Occurrence value ranking ... 24
Table 2.3 Detection value ranking ... 25
Table 2.4 Criteria of maintenance strategy based on RPN ... 25
Table 2.5 Literature review ... 32
Table 4.1 Downtime data ... 41
Table 4.2 Downtime data continue ... 42
Table 4.3 Cause of downtime curing machine... 42
Table 4.4 Cause of downtime curing machine continue ... 43
Table 4.5 Cause of M closing force problem ... 44
Table 4.6 MTBF and MTTR adjuster ... 49
Table 4.7 MTBF and MTTR crank gear ... 50
Table 4.8 FMEA of adjuster ... 51
Table 4.9 FMEA of crank gear ... 51
Table 4.10 New MTBF and MTTR adjuster ... 53
Table 4.11 New MTBF and MTTR adjuster continue ... 54
Table 4.12 New MTBF and MTTR crank gear ... 54
Table 4.13 New MTBF and MTTR crank gear continue ... 55
Table 4.14 Descriptive statistic data ... 58
Table 4.15 Reliability, maintainability, availability adjuster ... 59
Table 4.16 Reliability, maintainability, availability crank gear... 61
Table 4.17 Spare part replacement cost ... 62
Table 4.18 MTBF and MTTR after improve ... 64
Table 4.19 Reliability after improve ... 65
Table 4.20 Cost of preventive maintenance change bushing crank gear ... 67
Table 4.21 Cost because of downtime ... 67
Table 4.22 Saving cost about improvement ... 68
Table 4.23 Before after comparison ... 69
Table 4.24 Improvement progress ... 69
