e-Jurnal Teknik Industri FT USU Vol 3, No. 3, Oktober 2013 pp.

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MAINTENANCE MACHINE ACCORDINGLY PREVENTIVE

MAINTENANCE WITH
MODULARITY DESIGN ON PT. RXZ

Paul Tarigan 1 , Elisabeth Ginting 2 , Ikhsan Siregar 2

Department Technique Industry, Faculty Technique, University Sumatra

North Jl. Alma mater Campus USU, Medan 20155 Email:
pauluskarto@gmail.com
Email:
elisabeth.ginting@usu.ac.id
Email:ikhsan.siregar@usu.ac.id

Abstract . PT. RXZ is a company engaged in manufacturing, especially in infrastructure

section. One of the production factors whose use must be optimized as happened at PT. RXZ is
a production machine. Nowadays machines are used in production activities must be able to
operate optimally. PT. RXZ uses draft breakdown maintenance that is do maintenance after
machine experience damage. This method incurs huge repair costs because it has to replace
damaged components with new components. The aim of this research is to compare the
breakdown maintenance concept used by companies with the concept of preventive
maintenance. The method used in this research is preventive maintenance with a Modularity
Design approach. Modularity Design works to group machine elements according to the
sequence of the machine repair process. Using this concept can reduce production costs and
make the repair process simpler. Results Which obtained is cost maintenance machine with
use preventive modularity maintenance results in smaller total maintenance costs, namely:
Rp 49,902,964 compared to with cost maintenance breakdown Which total cost the
treatment reaches IDR 55,071,518. The percentage comparison of modularity designs is more
small 9.38% from breakdown maintenance so that method This appropriate used by
company.

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1. INTRODUCTION
Wrong One factor production Which must optimized its
use that is machine production. Machine Which used in
activity production must capable operate with optimal.
Operation machine It is said to be optimal if the
downtime value is minimum. For can ensure operation
machine Which optimal, required something system
maintenance And maintenance machine Which
appropriate. System maintenance machine Which
appropriate is system maintenance Which can provide a
minimum maintenance schedule downtime so that give
total cost Which minimum Also. Study Augustine Please,
Ronald Sukwadi, And Triphenaus Prabu Hidayat with
title “ Proposed Preventive Maintenance Using Method
Modularity Design on Machine Surface Mounting
Technology state that damage something component
Which No detected during The progress of the
production process can influence performance even
damage component other Which relate with
component Which concerned. Study This Also produce
something conclusion that maintenance machine with
design modular produce cost Which more A little
compared to with the method used at the company. PT.
RXZ is company manufacture Which processing river
stones. This type of river rock is gravel. To be able to
produce products in the form of crushed gravel, then
PT. RXZ requires stone crushing machine. There are 3
types of machines used by company This, that is double
jaw crushers , cone crushers And screen . In One O'clock
product Which generated Can reach 90 tons. Process
production done based on request or booking ( make to
orders ). Generally production Which generated ordered
by company Which move in the field construction And
relationship. Maintenance machine Which applied on
company that is breakdown maintenance. Type
maintenance the is technique maintenance machine
Which done For repair something part Which has
stopped For fulfill a condition for the machine to
operate optimally. Often a result of system
implementation Breakdown maintenance occurs when
other components are damaged when happen
replacement A component. Matter This because
damage Which No detected during The ongoing
production process affects performance from
component other Which relate with
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component Which concerned And even possible For
damage component the. On Finally, matter the will
result addition cost Which must issued by company to
replace the components involved become damaged.
Apart from that, there are costs as a result lost
production during ongoing process unscheduled repairs.
Therefore looking for it another way out for the engine
maintenance system. Method The proposed machine
maintenance system is preventive maintenance . System
maintenance This done in a way periodically And
continuous based on data historical engine damage in
the past. Preventive maintenance No only covers
timetable activity inspection but Also timetable
replacement component machine as action prevention
damage Which can happen on moment Which not
expected. For more efficient system preventive
maintenance , done grouping machines based on
function and process. Grouping This called with design
modularity .
2. METHOD STUDY
2.1. Place And Time Study
Study This done in PT. RXZ. Study This held on May
2012.
2.2. Object Study
Type study is study descriptive Which nature
comparative. It said descriptive Because study This try
For explained problem to something problem Which
There is Now in a way systematic And factual based on
data Which There is. This research is comparative in
nature because of this research carried out to get basic
answers about difference two method Which applied to
something system maintenance machine. Object study
is machine Which experience maintenance like machine
Jaw Crushers and Cone Crushers.
2.3. Design Study
On beginning study done studies introduction in the
form of observations of the Jaw Crusher machine and
Cone Crusher to find out the components machine that
is damaged, time interval damage machine, time
maintenance replacement
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component machine, amount power Work part
maintenance, price sell And profit product, price
component maintenance And function Work machine.
Furthermore grouping elements machine in accordance
with its function Which related. Step furthermore do
process calculation And comparison between
breakdown maintenance And modularity design .
Introduction to Statistics, selected distribution patterns
can be seen from mark Index of Fit ( Correlation
Coefficient ) the biggest. The distribution pattern tested
is distribution normal, lognormal, exponential and
weibull.
3.1. Determination Time Replacement Component

2.4. Variable Study The following table is a comparison of the length of time
Which required For do replacement component in a
The independent variable in this research is age way preventive And in a way breakdown in unit O'clock.
components and the absence of a maintenance
schedule. Variable dependent in study This is damage Table 1. Comparison Time Preventive with
machine. Breakdown
Time Time
Machine
2.5. Type Collection Data Breakdown Preventive
Components
Fix Jaw 6.58 6.12
Data Which used only form data secondary between Move Jaw 6.30 5.95
other station production, amount types machine Toggle
2.57 2.33
production, amount component maintenance Which Plates
needed, dot, dot, dot component maintenance on Jaw
Toggle
machine, order processing maintenance, intervals Crushers 3.81 3.39
Seats
damage component, time maintenance And Sip Plate 8,45 8,01
replacement of damaged components, labor costs Fan Belt 1,65 1,33
related to maintenance activities , selling price per units, Bearing 3,39 3,01
profit And capacity production per day along with with Fix Cone
price component purchases per units. 5,42 5,11
Plates
Mantle 5,60 5,13
2.6. Instrument And Technique Collection Data Cone
Fan 1,48 1,08
Crushers
Belts
Technique collection data in study This is 6,41 6,01
Cutting
Ring
observation, documentation And interview. In
Bearings 3.48 3.11
In this research, the research instrument used is
worksheets . Worksheets are used to record data
The table above shows the disassembly process time
research-related companies done. Data obtained from
And installation components each machine.
data collection, then processed to get an image
Components This taken based on data company Which
regarding preventive implementation modularity design
most often experience damage. From table can seen
.
comparison between time breakdown carried out by
the company over time preventive after carrying out the
3. RESULTS AND DISCUSSION
simulation. The result is time process maintenance
components machine more small from the initial state.
Data historical damage/failure machine Which used in
this research were taken from historical data year 2008
3.2. Analysis Cost Power Work
until year 2012. Furthermore data the used as analysis
For get machines And components critical. Furthermore
Cost power Work is cost power Work Which do
pattern damage component machine critical analyzed
replacement component on the machine.
based on data intervals damage component. According
Cost power Work consequence breakdown And
to Ronald E. Walpole in book preventive

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is:

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3.5. Analysis Cost Replacement Component with Use

Cost power Work = =
Modularity Design
6,888/person/hour

Table 3 below is the calculation result

3.3. Analysis Cost Loss of Production
replacement component machine in a way
modular.
Cost lost production determined based on output Which
should obtained Because lost production And profit
Table 3. Cost Modularity Design
production. Calculation cost loss of production namely
as following: Cpm Module Components (Rp)
Cost of Lost Production = Profit per ton x Output per Fix Jaw (jaw) Move Jaw
1 12.124.741
O'clock = Rp. 1000 x 90 tons/hour = Rp 90,000. (jaw) Sip Plate (jaw)
Toggle Plate (jaw) - 3.110.391
3.4. Analysis Cost Replacement Component
Toggle Seat (jaw) Fan
2 3.409.099
The cost of replacing components can be divided into Belt (jaw) Bearings (jaw)
two type, that is cost replacement breakdown And cost Fix Cone Plates (cone)
3 2.797.630
replacement preventive . Table 2 is results
calculation cost replacement in a way breakdown And Mantle (cone) 1 25,667,896
preventive .
Cutting Ring (cone)
Table 2. Cost Breakdown Maintenance (Cf) And Fans Belts (cone)
2 2,793,205
Preventive Maintenance (Cp) Bearings (cone)
Component Cf (Rp) Cp (Rp) Total 49,902,964
Fix Jaw (jaw) 6,682,846 6,084,355
Move Jaw (jaw) 6,654,134 6,081,967 Table on show cost process demolition
Toggle Plates (jaw) 3,266,704 3,032,098 And installation components each machine
Toggle Seats (jaw) 744,867 396,700 after done design modular. From table 2 And 3
OK Plates (jaw) 3,876,561 3,110,391 on can seen comparison cost breakdown
Fans Belts (jaw) 2,521,922 2,368,413 maintenance , preventive maintenance with
Bearings (jaw) 752,492 441,557 modularity design . Percentage comparison cost
Fix Cone Plates (cone) 12,562,465 12,070,349 with modularity design more small 9.38% from cost
Mantle (cone) 12,580,800 12,070,763 breakdown maintenance And more small 0.29%
from
Fans Belts (cone) 2,503,069 2,364,809 cost preventive maintenance .
Cutting Ring (cone) 2,164,858 1,582,748
Bearings (cone) 760,794 442,797
Total 55,071,518 50,046,953 4. CONCLUSION AND SUGGESTION

The table above shows the costs of the demolition

Based on results processing data And analysis data that
process and installation of components for each
has been done, it can be concluded that Determination
machine. From table can seen comparison between cost
hose time replacement component with use preventive
breakdown Which done company with cost preventive
modularity maintenance provides the best results in
after carrying out the simulation. The result is cost
terms of decline cost replacement component machine
process maintenance components machine more a little
that is machine Jaw Crushers And machine Cone
bit of the situation beginning.
Crushers. After determine the frequency of component
or module damage machine, preventive modularity
maintenance can done so that termination production
in a way arrive- suddenly can be avoided.

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Anggono, Willyanto, et al. 2005. Preventive

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Maintenance with Use Method Modularity
Design on Machine Surface Mounting
Technology (Study Case PT. X). Proceedings
Seminar National Technoin 2008 Field
Industrial Engineering.