Analisis Penyebab Kegagalan (Breakdown) untuk Penerapan Reliability Centered Maintenance (RCM) pada Mesin Cut Off di PT XYZ

Penelitian ini bertujuan untuk melakukan penerapan Reliability Centered Maintenance (RCM) pada mesin cut off dalam proses pembuatan pipa. RCM sendiri merupakan konsep dasar pemeliharaan yang berfokus pada keandalan mesin yang didalamnya menggunakan Failure Mode and Effect Analysis (FMEA) dan Logic Tree Analysis (LTA) untuk mengetahui komponen rusak pada mesin dan penyebab kerusakannya serta usulan perbaikan terhadap kerusakan mesin. Sebelumnya, perhitungan Overall Equipment Effectiveness (OEE) dilakukan untuk mengetahui tingkat efektivitas mesin dan nilai OEE yang diperoleh adalah 16.75%. Pehitungan reliabilitas juga dilakukan sebagai dasar untuk menganalisis penyebab kerusakan pada mesin dan nilai reliabilitas yang diperoleh adalah 39.68%. Dari hasil FMEA diketahui sepuluh komponen kritis pada mesin cut off diantaranya: gearbox , limit switch , rantai, adjuster pisau, feeding wheel , CLM, cylinder feeding , guide rail , sliding block set , dan measuring wheel . Komponen kritis tersebut didapat berdasarkan perhitungan Risk Priority Number (RPN). Hasil dari LTA menunjukkan bahwa mode kerusakan yang terjadi pada setiap komponen kritis masuk ke dalan kategori B ( outage problem ). Kerusakan yang terjadi banyak disebabkan oleh penggunaan komponen yang melewati lifetime -nya. Usulan tindakan perbaikan yang diberikan berupa penjadwalan penggantian komponen yang baru, pembersihan dan pengecekan rutin terhadap mesin sebelum dan sesudah proses produksi dilakukan. Kata Kunci: RCM, OEE, reliabilitas, FMEA, RPN, LTA This study aims to perform the application of Reliability Centered Maintenance (RCM) on cut off machine in pipe manufacturing process . RCM itself is a basic concept of maintenance that focuses on reliability of machine which includes using Failure Mode and Effect Analysis (FMEA) and Logic Tree Analysis (LTA) to determine the damaged components and their failure causes and proposed improvement actions. Previously, the calculation of the Overall Equipment Effectiveness (OEE) was conducted to determine the effectiveness of machine and OEE value obtained is 16.75%. Calculation of reliability was also performed as a basic for analyzing the causes of machine failure and reliability value obtained is 39.68%. The FMEA results revealed ten critical components of cut off machine such as gearbox, limit switch, chain, knive adjuster, feeding wheel, CLM, cylinder feeding, guide rail, sliding block ses, and measuring wheel. Critical components was determined by the calculation of Risk Priority Number (RPN). Results of LTA showed failure modes that occur in every critical component merge into category B (outage problem). Failures that occur mostly caused by the use of components that pass over its lifetime. Proposed corrective actions are routine scheduling for new components replacement, cleaning and checking the machine before and after the production process. 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