MAINTENANCE SYSTEM

Bentuk / Sistem Perawatan :

- Perawatan Preventif ( Preventive Maintenance )

- Perawatan korektif ( Corrective Maintenance )
- Perawatan berjalan ( Running Maintenance )
- Perawatan Prediktif ( Predictive Maintenance )
- Perawatan setelah terjadi kerusakan ( Breakdown
Maintenance )
- Perawatan Darurat ( Emergency Maintenance )

Cara lain pengganti perawatan :

- Perawatan dengan cara penggantian ( Replacement instead

of maintenance )
- Penggantian yang direncanakan ( Planned replacement )
 IMPORTANCE OF MAINTENANCE
 Production capacity:
Machines idled by breakdowns cannot produce, thus the capacity of the system is
reduced.
 Production costs:
Labor costs per unit rise because of idle labor due to machine breakdowns. When
machine malfunctions result in scrap, unit labor and material costs increase. Besides,
cost of maintenance which includes such costs as costs of providing repair facilities,
repair crews, preventive maintenance inspections, spare parts and stand by
machines will increase as machines break down frequently.
 Product and service quality:
Poorly maintained equipments produce low quality products. Equipments that have
not been properly maintained have frequent break downs and cannot provide
adequate service to customers. For example, air craft fleets of the airline, railway and
road transport services not maintained well can result in poor service to customers.
 Employee or customer safety:
Worn-out equipment is likely to fail at any moment and these failures can cause
injuries to the workers, working on those equipments. Products such as two wheelers
and automobiles, if not serviced periodically, can break down suddenly and cause
injuries to the stress.
 Customer satisfaction:
When production equipments break own, products often can not be produced
according to the master production schedules, due to work stoppages. This will lead
to delayed deliveries of products to the customers.
 OBJECTIVE OF MAINTENANCE
 Minimizing the loss of productive time because of equipment failure
(i.e. minimizing idle time of equipment due to break down).
 Minimizing the repair time and repair cost.
 Minimizing the loss due to production stoppages.
 Efficient use of maintenance personnel and equipments.
 Prolonging the life of capital assets by minimizing the rate of wear
and tear.
 To keep all productive assets in good working conditions.
 To maximize efficiency and economy in production through optimum
use of facilities.
 To minimize accidents through regular inspection and repair of
safety devices.
 To minimize the total maintenance cost which includes the cost of
repair, cost of preventive maintenance and inventory carrying costs,
due to spare parts inventory.
 To improve the quality of products and to improve productivity.
 TYPES OF MAINTENANCE SYSTEM
Maintenance
System

Planned Unplanned
(Work organized and carried (Emergency maintenance work
with forethought, control and caused by unforeseen damage and
record) accidents)

Preventive maintenance Corrective maintenance

(Work intended to preserve (Work intended to restore
an asset, to prevent failure an asset, to the acceptable
and to delete incipient standard)
faults)

Running Shutdown Breakdown maintenance

maintenance maintenance (Work implemented after failure
(Asset is in operation) (Asset is out of but based on advance planning)
service)

Scheduled Reliability-based
Maintenance Maintenance Repair Replacemen Overhaul
t
Conditioned-based
Maintenance
 BREAKDOWN MAINTENANCE (BM)
Breakdown maintenance is maintenance performed on
equipment that has broken down and is unusable. It is
based on a breakdown maintenance trigger. It may be
either planned or it can be unplanned.
LIMITATION OF BM :
• Unpredictability 
– which result in either labour or materials being unavailable
– therefore delay in time taken for a repair, increasing equipment downtime
– can result in unnecessarily expensive charges that may have been avoided
– can also affect budgets and cost planning
• Equipment not maximised 
– reduces the lifespan of the unit
– the equipment won’t fulfill its potential or return on investment.
• Indirect costs 
– equipment downtime/ unreliable equipment causing negative effects on
reputations, safety and the ability to run a business efficiently and productively
– inefficient use of employee time.
 PLANNED MAINTENANCE (PM)
The planned maintenance is an organized type of
maintenance, which takes care of other aspects such as
control and records required for this type of work.
Method :
• First of all, a work study has to be carried out to decide the periodicity/
frequency of the maintenance work.
• Time study can also suggest the ways and means of devising optimal
maintenance schedules for the given system.

Features :
• The work is planned beforehand to avoid random failures.
• It decides ‘Who’ will carry-out 'what‘ maintenance work, by 'when’.
• Specific instructions for each type of equipment have to be provided in
greater detail .
• The type of maintenance job will depend upon the nature of equipment and
its working conditions.
 SCHEDULED MAINTENANCE (SM)
In this type of maintenance work, the actual maintenance
program is scheduled in consultation with the production
department, so that the relevant equipment is made available
for maintenance work.
Method :
• The frequency of such maintenance work is pre-determined from
experiences.
• In this way, the where and when of the maintenance work can be
approximated by most efficient use of the idle time of equipment.
Features :
• It utilizes the idle time of the equipment effectively.
• This also helps the maintenance department to use their manpower
effectively.
• The specialists for a particular work can also be made available during the
maintenance period as the schedule is known in advance.
• Though scheduled maintenance is costly compared to breakdown
maintenance, the availability of equipment is enhanced.
 PREVENTIVE MAINTENANCE
Preventive maintenance is the utilization of planned and
coordinated inspections, adjustments, repairs and replacements
needed in maintaining an equipment or plant.
Features :
• Detection of any condition that may cause machine failure before
such breakdown occurs.
• This makes it possible to plan and schedule the maintenance work
without interruption in production schedule and thus improves the
availability of equipment.
• A systematic and extensive inspection of each item of equipment
(or the critical parts) is made at predetermined intervals.
Method :
• Routine attention: This involves maintenance activities that take
regular care of the machines or assets. These activities are designed
to preserve the assets of the organization at a given standard of
maintenance, which conforms to its financial and operating policies.
Routine servicing includes cleaning, oiling, and adjusting.
 PREVENTIVE MAINTENANCE
Method :
Contd..
• Routine examination : Routine examinations are carried out to
identify dormant faults or items prone to failure. This type of
preventive maintenance work helps to detect faults before they
can actually occur.
• Preventive replacement : The preventive maintenance work
comprises preventive replacement of parts and components
that have a definite life. Such type of replacements help to
avoid emergency situations and prolonged downtime and risk
of hazards associated with sudden breakdowns.
• Inspection measurements : Inspection measurements
comprise jobs of preventive maintenance that aim at identifying
the degradation rate of items, and such other items which are
at unacceptable service conditions. This type of maintenance
work requires many costly instruments and laboratory testing
facilities
 MAINTAINABILITY
It is expressed as the probability that an item
will remain in a serviceable condition for a
given period of time.
Maintainability is also expressed in terms of the
minimum cost of maintenance as well as the
accuracy of the maintenance function.
 MAINTAINABILITY
Contd…
Mean Time to Repair (MTTR) : The parameter for
expressing the maintainability i.e. how much time
is required to restore the equipment/ system to its
working condition.

Failure Rate (FR) or Mean Time Between Failures

(MTBF) : The parameters expressing reliability,
which is defined as the probability that an asset or
a system will operate satisfactorily for a pre-
determined period of time, under the working
conditions for which it was designed.
Bentuk / Sistem Perawatan
 
A. Perawatan Preventif ( Preventive Maintenance )

Pekerjaan perawatan yang bertujuan untuk mencegah terjadinya kerusakan,

atau cara perawatan yang direncanakan untuk pence­gahan (preventif).
Perawatan preventif dimaksudkan juga untuk mengefektifkan pekerjaan
inspeksi, perbaikan kecil, pelumasan dan penyetelan se­hingga peralatan atau
mesin-mesin selama beroperasi dapat terhin­dar dari kerusakan. Perawatan
preventif dilaksanakan sejak awal sebelum terjadi kerusakan.
Perawatan preventif ini penting diterapkan pada industri-industri yang proses
produksinya kontinyu atau memakai sistem otomatis, misalnya:
Pabrik kimia, industri pengerolan baja, kilang minyak, produksi masal dan
sebagainya.
Apabila terjadi kemacetan produksi karena adanya kerusakan dapat
menimbulkan biaya yang sangat tinggi.
Apabila terjadi kerusakan kecil pada bagian fasilitas yang vital dapat
mengakibatkan kegagalan seluruh proses.
Apabila kegagalan atau kerusakan yang terjadi sangat membaha­yakan, seperti
pada ketel, bejana bertekanan, alat pengangkat dan sebagainya.
B. Perawatan Korektif ( Corrective Maintenance )

Pekerjaan perawatan yang dilakukan untuk

memperbaiki dan meningkatkan kondisi fasilitas
sehingga mencapai standar yang dapat diterima.
Perawatan korektif termasuk dalam cara perawatan
yang direncanakan untuk perbaikan.
Dalam perawatan korektif ini dapat mengadakan
peningkatan-peningkatan sedemikian rupa, seperti
melakukan perubahan atau modifikasi rancangan
peralatan agar lebih baik. Menghilangkan problems
yang merugikan untuk mencapai kondisi operasi
yang lebih ekonomis.
C. Perawatan Berjalan ( Running Maintenance )

Pekerjaan perawatan yang dilalcukan pada saat

fasilitas atau per­alatan dalam keadaan bekerja.
Perawatan berjalan ini termasuk cara perawatan
yang direncanakan untuk diterapkan pada
peralatan dalam keadaan operasi.
Perawatan dalam kondisi berjalan diterapkan pada
mesin-mesin yang harus beroperasi terus dalam
melayani proses produksi. Kegiat­an perawatan
dilakukan dengan jalan monitoring secara aktif.
Diha­rapkan hasil dari perbaikan yang dilakukan
secara cepat dan terenca­na ini dapat menjamin
kondisi operasi produksi tanpa adanya gangguan
yang mengakibatkan kerusakan.
D. Perawatan Prediktif ( Predictive Maintenance )

Perawatan prediktif ini dilakukan untuk mengetahui

terjadinya perubahan atau kelainan dalam kondisi
fisik maupun fungsi dari sis­tem peralatan. Biasanya
perawatan prediktif dilakukan dengan bantuan
pancaindera atau dengan alat alat monitor yang
canggih. Teknik-teknik dan alai bantu yang dipakai
dalam memonitor kondisi ini adalah untuk efisiensi
kerja agar kelainan yang terjadi dapat diketahui
dengan cepat dan tepat. Perawatan dengan sistem
monitoring sangat penting dilakukan untuk
mendapatkan hasil yang realistis tanpa melakukan
pembongkaran total untuk menganalisisnya.
E. Perawatan setelah terjadi kerusakan ( Breakdown
Maintenance )

Cara perawatan yang direncanakan untuk memperbaiki

keru­sakan. Pekerjaan perawatan ini dilakukan setelah
terjadi kerusakan, dan untuk memperbaikinya harus
disiapkan suku cadang, material, alat-alat dan tenaga
kerjanya.
Beberapa peralatan pabrik yang beroperasi pada unit
tersendiri atau terpisah dari proses pembuatan, tidak akan
langsung mempe­ngaruhi seluruh proses produksi apabila
terjadi kerusakan. Untuk peralatan tersebut tidak perlu
diadakan perawatan, karena biaya perawatan lebih besar
daripada biaya kerusakannya. Dalam kondisi khusus ini
peralatan dibiarkan beroperasi sampai terjadi kerusakan,
sehingga waktu untuk produksi tidak berkurang.
Penerapan sistem perawatan ini dilakukan pada mesin-
mesin industri yang ringan, apabila terjadi kerusakan dapat
diperbaiki dengan cepat.
F. Perawatan Darurat (Emergency
Maintenance)

Pekerjaan perbaikan yang segera dilakukan

karena terjadi kemacetan atau kerusakan
yang tak terduga. Perawatan darurat ini
termasuk cara perawatan yang tidak
direncanakan (unplanned emergency
maintenance).