PHYSICAL AVAILABILITY

AGENDA
 INTRODUCTION
• PENGERTIAN PHYSICAL AVAILABILITY
• PHYSICAL AVAILABILITY PLANNING
• FORMULA PHYSICAL AVAILABILITY
• CONTOH PERHITUNGAN PHYSICAL AVAILABILITY

 REVIEW PHYSICAL AVAILABILITY 2008

 PLAN PHYSICAL AVAILABILITY 2009
 KONSEP DASAR

 OPERATION/PRODUCTION ADALAH CUSTOMER KITA (PLANT)

PENGERTIAN PHYSICAL AVAILABILITY

 Sebuah parameter yang menunjukkan persentase ketersediaan alat

 Dimana Phisical Availability dipengaruhi factor –factor sebagai berikut :

1. Working Hour
2. Stanby Hour
3. Breakdown Hour
4. MOHH (Machine On Hand Hour )
 PHYSICAL AVAILABILITY PLANNING

 DATA DAN PERHITUNGAN

Dasar perhitungan untuk merencanakan sebuah Availability adalah

MAINTENANCE PLANNING:
1. Unit Model
2. Update Hour Meter
3. Component List
4. Component Life Time
5. Working Hour

PHYSICAL AVAILAILITY
PLANNING
 COMPONENT LIFE TIME

Factory or Distributor
Information

References from Similar

Machine

Experience from Old

Machine

Company Policy
 Standard Man Hour for Repair

Factory or • Komatsu  StanRate

• Volvo  Prosis &
Dealer DVD Impact
Information • Caterpillar  SIS

References
from Similar
Machine

Experience from
Old Machine
 PARAMETER PENGUKUR PHYSICAL AVAILABILITY

WORKING HOUR STANBY HOUR BREAKDOWN HOUR

± 15 HOUR/DAY Tidak ada operator B1 : Waiting part

  Hujan lebat B2 : Waiting mechanic

  kabut B3 : On Process

  Makan, Istirahat B4 : External Service

  Scrap Jalan B5 : Accident

    B6 : Others
 PERHITUNGAN AVAILABILITY UNIT

 FORMULA

PHYSICAL AVAILABILITY (PA)

WH + STB
PA = × 100%
MOHH

UTILITY AVAILABILITY (UA)

KETERANGAN
• WH :Working Hour
WH
• STB : Stanby Hour
UA = × 100%
• BD : BreakDown Hour
MOHH
• MOHH :
 WH + STB + BD
MOHH = Waktu yang tersedia untuk unit beroperasi (24 hour/day)
  CONTOH PERHITUNGAN

A. PA PLANNING

DATA:

UNIT HD 465-7
HOUR METER = 8000

TENTUKAN PLAN PA UNTUK 1 BULAN KEDEPAN?

?
  DATA PERHITUNGAN
LIFE MAN HOUR BY SIS FLAT RATE PARTIAL
MODEL COMPONENTS/PART QTY
TIME REB R&I REB TOT R&I TOT TOT REB TOT R&I TOT TOT REB TOT R&I TOT TOT

   
HD465-7 CYLINDER HEAD SET 1 8000 16 6 16 6 22 16 6 22 16 6 22
HD465-7 INJECTOR NOZZLE SET 1 8000 8 8 8 8 16 8 8 16 8 8 16
HD465-7 FUEL INJECTION PUMP 1 8000 16 8 16 8 24 16 8 24 16 8 24
HD465-7 WATER PUMP 1 8000 12 8 12 8 20 12 8 20 12 8 20
HD465-7 FAN DRIVE & PULLEY 1 8000 6 7 6 7 13 6 7 13 6 7 13
HD465-7 TENSION PULLEY 1 8000 6 7 6 7 13 6 7 13 6 7 13
HD465-7 TURBOCHARGER 1 8000 8 0 8 - 8 8 - 8 8 - 8
TURBOCHARGER
HD465-7 MOUNTING 1 8000 6 4 6 4 10 6 4 10 6 4 10
HD465-7 ALTERNATOR 1 8000 8 2 8 2 10 8 2 10 8 2 10
HD465-7 STARTING MOTOR 2 8000 6 2 12 4 16 12 4 16 12 4 16
AIR COMPRESSOR &
HD465-7 MOUNT 1 8000 10 6 10 6 16 10 6 16 10 6 16
HD465-7 FRONT DRIVE SHAFT 1 8000 10 7 10 7 17 10 7 17 10 7 17
HD465-7 REAR DRIVE SHAFT 1 8000 10 7 10 7 17 10 7 17 10 7 17
HD465-7 FRONT SUSPENSION 2 8000 35 16 70 32 102 70 32 102 70 32 102
HD465-7 REAR SUSPENSION 2 8000 35 4 70 8 78 70 8 78 70 8 78
HD465-7 AIR DRYER 1 8000 9 4 9 4 13 9 4 13 9 4 13
HD465-7 AIR GOVERNOR 1 8000 3 4 3 4 7 3 4 7 3 4 7
HD465-7 AC RELATED PARTS 1 8000 0 10 - 10 10 - 10 10 - 10 10

TOTAL MAN HOUR         280 132 412 280 132 412 280 132 412
  PART SERVICE

PART PRICE MAN

UNIT MODEL
NUMBER
DESCRIPTION QTY LIFE TIME
USD
AMOUNT
HOUR

   

KOMATSU HD465-7 600-211-1231 FULL FLOW FILTER 2 500 11.08 22.17 1.00

KOMATSU HD465-7 600-311-3110 FUEL FILTER 3 500 85.11 255.34 1.50

TRANSMISSION
KOMATSU HD465-7 424-16-11140 FILTER 2 500 7.43 14.86 1.00
TOTAL MAN
          HOUR   3.50

UNIT MODEL OIL COMPONENT QTY LIFE TIME PRICE PER AMOUNT
LITTER
MAN
HOURS

KOMATSU HD465-7 SAE 30 ENGINE 57 500 1.80 102.60 0.86

KOMATSU HD465-7 NLGI-2 GREASE 20 250 2.66 53.20 0.30
KOMATSU HD465-7 SAE 30 TRANSMISSION 89 500 1.80 160.20 1.34
TOTAL MAN
HOUR 2.50
  PERHITUNGAN

BREAKDOWN HOUR :
1. PERIODICAL SERVICE
a. SERVICE 250
i. CUCI = 1 JAM
ii. PENGECEKAN OLI +PART = 1 JAM
b. SERVICE 500
i. CUCI = 1 JAM
ii. PENGGANTIAN PART SERVICE =3.5 JAM =1.75 JAM (2 ORANG)
iii. PENGGANTIAN OLI =2.5 JAM =1.25 JAM (2 ORANG)
2. PELAKSANAAN MIDLIFE =412 JAM /MAN POWER = 103 JAM (4 ORANG)

TOTAL BREAKDOWN HOUR SCHEDULE =109 JAM

SAFETY FACTOR UNSCHEDULE 10% × 109 JAM =10.9 JAM

TOTAL BREAKDOWN HOUR (SC+ UN SC) =129.9 JAM

MOHH (24×30) =720 JAM

  JADI PLANNING PA KITA ADALAH :

BREAKDOWN HOUR (BD) = 129. 9 JAM

MOHH = 720 HOUR

PHYSICAL AVAILABILITY (PA)

MOHH -BD 720-129.9

PA = ×100% = ×100%
MOHH 720

= 81.9 %
  CONTOH PERHITUNGAN
2. PA ACTUAL
WORKING HOUR (WH) = 13 HOUR
BREAKDOWN HOUR (BD) = 7 HOUR
MOHH = 24 HOUR
STANBY HOUR (STB) = MOHH – (WH+BD)
= 4 HOUR

PHYSICAL AVAILABILITY (PA)

WH + STB 13 + 7
PA = ×100% = ×100%
MOHH 24

= 83.3 %
  CONTOH PERHITUNGAN
3. UTILITY AVAILABILITY

WORKING HOUR (WH) = 13 HOUR

BREAKDOWN HOUR (BD) = 7 HOUR
MOHH = 24 HOUR
STANBY HOUR (STB) = MOHH – (WH+BD)
= 4 HOUR

UTILITY AVAILABILITY (UA)

WH 13
UA = ×100% = ×100%
MOHH 24

= 54 %
 REVIEW PHYSICAL AVAILABILITY 2008

 REVIEW PHYSICAL AVAILABILITY WEEKLY 2009

 REVIEW BREKDOWN UNIT

 Parameter service
PA = Physical Availibility
Jumlah jam operasi unit + Stand by
X 100%
MOHH

MOHH = Waktu yang tersedia untuk unit beroperasi ( 24 x Periode)

MTTR = Mean time to repair (Rata – rata waktu untuk mengerjakan repair)

Total waktu repair

Frekuensi B/D

MTBF = Mean time between failure (Rata – rata alat sebelum terjadi kerusakan)

Jumlah jam operasi

Frekuensi B/D
 TERIMA KASIH

MUDAH UNTUK BERMIMPI SETIAP

MALAM

TETAPI SULIT UNTUK BERTARUNG

UNTUK SEBUAH IMPIAN