Modul 14

Manajemen Pemeliharaan

14.01
Pendahuluan
Dr. Ir. Rachman Setiawan
Teknik Mesin – FTMD ITB Alat Angkat – Alat Angkut – Alat Berat

1
 Overview
• Mechanical Eqpt. In Mining Industry
• Stationary Equipment • Moving Equipment
• Crusher • Haul truck
• Conveyor • Shovel/Back hoe
• Stacker • Mobile crane
• Reclaimer • Scrapper, Grader
• Buldozer, Wheel dozer
• Wheel loader

2
 Overview
• Level of Operation Severity:
• Constant Speed, Constant Load
• Constant Speed, Variable Load
• Variable Speed, Constant Load
• Variable Speed, Variable Load

3
 Overview
• Definition
Maintenance is a series of activities (technical and administrative) needed to
hold or keep an item (product or system) in its safe, economic, efficient, and
optimal operation

• Why do we need maintenance?

• Every equipment have a USEFUL LIFE. Some how, some time IT MUST FAIL.
• We do not know EXACTLY when the equipment will FAIL.
• Man try to make every effort to MAXIMIZE the USEFUL LIFE by doing
MAINTENANCE.

4
 Overview
• Life Cycle Cost
• One often addresses only the SHORT-
TERM COST (the initial procurement of
a system/product, inc. Design,
development, and production cost).
• LONG-TERM COST (operation and
maintenance support) are often
HIDDEN).
• In many cases, experience has indicated
that long-term cost often constitute a
large percentage (UP TO 75%) of the
total LCC.
• Thus, the LACK of total cost visibility,
result in POOR Maintenance
Management Strategy.

5
 Overview
• Bath-Tub Curve
• Start up cycle
• Failures due to pada workmanship, materials,
installation, operator training.
• Lack of historical data
• Failures are difficult to predict
• Goal of maintenance: to minimize failure
consequences
• Wealth cycle
• Productive cycle of equipment
• With a good management, sufficient historical data
• Goal of maintenance: to keep the asset in this cycle
(or better extend this cycle)
• Breakdown cycle
• Failurus due to lifetime (wear, corrosion, fatigue)
• Goal of maintenance: tp detect and predict the
breakdown and overhoul → wealth cycle

6
 Overview
• Maintenance Time Relationship
Time

Uptime Downtime

Operating Standby Active maintenance Logistic Administrative

time time time time time

7
7
 Overview
• UPTIME: period of time when machine/equipment is in good and working
condition as intended within its operating and maintaining condition

• DOWNTIME: period of time when machine/equipment is NOT in good and

working condition as intended. Downtime is calculated starting from the time
when it fails to fulfill its intended function until stated to be functioning after
repair

• OPERATING TIME: period of time when machine/equipment is used as its

intended function.

• STANDBY TIME: period of time when machine/equipment is in good and

working condition as intended BUT NOT operated for some reasons.
STAND BY TIME = UPTIME - OPERATING TIME
8
 Overview
• MAINTENANCE TIME : period of time when machine/equipment is
undergone maintenance action including delays during the downtime

• ACTIVE MAINTENANCE TIME: the actual time when the maintenance WORK is
carried out
• LOGISTIC TIME: period of time when maintenance work cannot be carried out
due to logistic reasons, e.g. waiting for the parts/tools, travel time etc.
• ADMINISTRATIVE TIME: period of time when maintenance work cannot be
carried out due to administrative reasons, e.g. paper work, IT system, WO
generation, reporting.

9
 Overview
• Availability: • Mean Time Between Failures (MTBF):

Uptime σ Uptime
Availability = MTBF =
Total Time No. failures

• Failure rates:

1
𝜆=
MTBF

10
 Overview

Down Time
2.1 hr 7.1 hr 4.2 hr 1.8 hr 3.5 hr 2.1 hr

24.4 hr 7.1 hr 27.4 hr 35.3 hr 6.3 hr 46.7 hr 5.0 hr

Up Time

System Operational Cycle – 169 Hours → Total Time

Maintenance Actions due to Planned or Unplanned Maintenance

• Availability??
• Mean time between failures (MTBF)??
11
 Overview
• Intended Function
• In defining availability, it is important to separate whether an equipment is in
fuction or fail condition
• An equipment is said to function if it is fulfilling its intended set of functions
• For example, intended function of a hydraulic pump is:
• Deliver hydraulic oil at minimum flow rate of … lpm
• Deliver hydraulic oil at minimum head of … m (discharge pressure of …. Bar min.)
• Take a power of maximum of … kW
• No visible leakage
• Vibration within standard allowable limit
• …
• If one or more function is not fulfilled, the equipment is said to be failed
• It is important that there is an agreement between operation/production and
maintenance on this definition
12
 Overview
• Reliability
𝑡
−𝜃
𝑅(𝑡) = 1 − 𝐹(𝑡) = 𝑒 = 𝑒 −𝜆𝑡

Where
Decreasing
failure rate
Increasing
failure rate
• F(t) : probability of failure at observation time, t
• q : mean life / mean time between failure (MTBF)

13
 Modul 14
Manajemen Pemeliharaan

14.02
Strategi
Dr. Ir. Rachman Setiawan
Teknik Mesin – FTMD ITB Alat Angkat – Alat Angkut – Alat Berat

14
 Maintenance Strategy
• Maintenance Strategy:
• Planned/Scheduled/Proactive:
• to prevent failure from happening
• to detect any degradation
• to predict productive life
• to extend its lifetime

• Unplanned/Unscheduled/Breakdown
Fix it when it breaks

Definition
Maintenance is a series of activities (technical and
administrative) needed to hold or keep an item
(product or system) in its safe, economic, efficient,
and optimal operation

15
 Maintenance Strategy
Preventive Activities that either prevent, extend the life of an
asset, detect that an asset has had critical wear
point and is going to fail or breakdown
Planned

Predictive Activities that inspect an asset to detect and

predict if a failure will occur

MAINTENANCE
Corrective Activities that restores an asset to a preserved
condition during routine maintenance, that
involves no downtime. Normally initiated as a
result of a scheduled inspection

Corrective Activities that restores an asset to a preserved

Un-planned condition, that involves short downtime

Breakdown Activities to restore an asset to its stated

operation condition (Fix it when it breaks), that
involves significant downtime

16
 Maintenance Strategy
• Maintenance Category
• Preventive maintenance: Activities that either prevent, extend the life of an
asset, detect that an asset has had critical wear point and is going to fail or
breakdown
• Predictive maintenance: Activities that inspect an asset to detect and predict
if a failure will occur.
• Corrective maintenance: Activities that restores an asset to a preserved
condition. Normally initiated as a result of a scheduled inspection, incident or
manufacturing defects.
• Breakdown maintenance: Activities to restore an asset to its stated operation
condition (Fix it when it breaks). It Is not exactly maintenance activity.
Included in this category are all unscheduled activities due to breakdown
failure of equipment.

17
 Maintenance Strategy
• Examples
• Overhaul
Preventive
• Change component
• Service
Planned • Initial service
• Condition-based monitoring :
Predictive
Oil analysis, VIMS/VHMS, Fluid consumption report,
Wear analysis, Sibas/Statec III
• Modification :
Failure analysis, Engineering modif., Commissioning,
Risk assessment, Accident report recommendation,
Trial/improvement recommendation
MAINTENANCE
• Pre-entry/Pre-release backlog
Corrective
• PM inspection
• Inspector report backlog
• Follow up action work backlog
• Defect report/Pre-entry/Pre-release

• Incident
Corrective
• Defect
Un-planned
Breakdown
18
 #Exercise (Planned/Unplanned ?)
• Mengatur kontrol temperatur pada suatu peralatan sampai siap operasi
P
• Membetulkan mirror haul truck U
• Kalibrasi alat ukur secara berkala P
• Pengaturan tegangan pada drive belt P
• Mengganti pompa setelah impeller pecah U
• Mengganti bearing karena macet U
• Mencatat besaran-besaran pada alat ukur P
• Overhaul engine P
• Penambahan oli setiap 6000 km P
• Mengganti pompa setiap lima tahun P
• Mengganti roda gigi patah karena panas U
• Informasi performans mesin selama operasi P
• Melakukan analysis sejarah suatu peralatan/mesin P
19
 Modul 14
Manajemen Pemeliharaan

14.03
Manajemen Kerja
Dr. Ir. Rachman Setiawan
Teknik Mesin – FTMD ITB Alat Angkat – Alat Angkut – Alat Berat

20
 Work Management

All about
All about
WHEN each
HOW work WHAT to do
job gets done
is identified for each job

All about All about All about

LEARNING DOING each WHO does
from each job job right each job

21
 Work Management
• Work Identification: WHICH WORK
• Equipment/system fail (break down)
RCM result in the precise
• We discover something that’s wrong, but it identification of work
is still working
• We think that something wrong but can’t IDENTIFY PLAN SCHEDULE
prove it.
• We do preventive replacements EMERGENCY

• We look for signs of things going wrong -

from condition monitoring/predictive. CLOSE EXECUTE ASSIGN
• We test system to find things (dormant
system)
• Engineering identifies work needed (up-
grades, tie-ins, modifications, new systems)

22
 Work Management
• Work Planning: WHAT TO DO
• Job scope Every non-trivial should be planned
• Job procedure (steps) and saved as a “standard job)
• Resources required:
• Skills IDENTIFY PLAN SCHEDULE
• Parts
• Tools/equipment EMERGENCY
• Manual, instruction, work permit
• Duration estimation CLOSE EXECUTE ASSIGN
• Cost estimation

23
 Work Management
• Work Scheduling: WHEN
• Schedules are based on work priority and Scheduling information is contained
criticality in CMMS
• Schedule work for execution only when all
resources available
• Can be adjusted as priority shifts due to IDENTIFY PLAN SCHEDULE

additional work arising

• Scheduling cycles: daily, weekly, monthly,
EMERGENCY

annual, or strategic.
CLOSE EXECUTE ASSIGN

24
 Work Management
• Work Assignment: WHO
• Supervisors assign work
• Planners decide what skill/trades are needed
• Schedulers say when they are available IDENTIFY PLAN SCHEDULE
• Supervisors have the choice based on:
• Who’s working that day and how many are needed? EMERGENCY
• Who’s skills are best matched to the job?
• Who is the best for the job? CLOSE EXECUTE ASSIGN
• Who needs to learn the job?
• Who can teach the best?
Supervisors manage theirs crews

25
 Work Management
• Work Execution: DOING
• Must have all resources he need to get the
job done quickly (parts, tools, instruments,
permits, etc.) IDENTIFY PLAN SCHEDULE
• Determine:
• Timeliness EMERGENCY
• Quality
• Parts CLOSE EXECUTE ASSIGN
• Cost
• Training is critical
Trades execute the work and control
the quality of the work that gets done

26
 Work Management
• Work Closing: LEARN
• No job is complete until we close it off and
learn from it
• Close the W/O to clear the job from backlog IDENTIFY PLAN SCHEDULE
• Record what was learned, include:
• What work well EMERGENCY
• What did not work well
• What did you learn about the equipment CLOSE EXECUTE ASSIGN
• What follow up actions are needed based on what
was learned
• Information from this will be useful for:
Trades provide most of the input, supervisors
• Reliability analysis
ensure it is accurate, reliability engineering
• Planning feedback support and management uses it.
• Operations feedback

27
 Work Management
• Who does what

IDENTIFY • Anyone, usually operation

PLAN • Planner (may be assisted by field inspector)

SCHEDULE • Planner or Scheduller

ASSIGN • Supervisor

EXECUTE • Trades and operations

CLOSE • Trades, supervisor, planner

• Follow up as necessary by planner & reliability engineering
28
 Work Management
• Impelementation →
• Work Order
• Computerized Maintenance Management
System (CMMS) software

29
30