01

MAINTENANCE CONCEPT
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Y
R Predictive Maint.
O
T • Condition-based maint.
IS • Deteksi gejala kerusakan
H • Prediksi kapan akan rusak
E • Jadwalkan perbaikan sbl rusak
C
N
A 3rd Generation
N
E
T Preventive Maint.
IN • Maint. Periodic terjadwal
A • Replace/rebuild secara periodic
M
sesuai standar umur

2nd Generation
Corrective/Unplanned Maint.
• Tidak ada program maint
• Operasikan sampai rusak, baru Dimanakah kita sekarang ?
lakukan perbaikan

apa misi jangka panjang kita ?

1st Generation
apakah kita mendapat vendor support ?
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CORRECTIVE MAINTENANCE

• Siklus
Operate
Anda tidak perlu melakukan apapun
Failed
sampai terjadi kerusakan, kemudian
perbaiki !

Repair

REACTIVE MAINTENANCE
· Tak ada waktu utk menganalisa kerusakan
· Perbaiki hanya jika rusak
· Tak ada data untuk dipelajari
· Semua aktivitas adalah UNSCHEDULED !

VERY HIGH MAINTENANCE COST

· Lembur
· Loss production
· Inventory tinggi
· Resiko tinggi

SHORT COMPONENT LIFE

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PREVENTIVE MAINTENANCE

• Siklus
Operate Ganti komponen mesin Anda
Periodic
maintenance secara periodic sesuai standar
umurnya, tidak peduli komponen
itu masih bisa diperpanjang
Periodic umurnya atau tidak !
Operate maintenance
LOW RISK Run Periodic
• Kepastian aktivitas maint. Tinggi
• Unscheduled breakdown turun Maint. Schedule !

MODERATELY HIGH MAINT. COST

• Waktu dan biaya kurang efisien
• Production loss dari unscheduled downtime masih ada

SCHEDULE
MAINT.
SHORT COMPONENT LIFE
• Tak ada upaya perpanjangan umur komponen
· Tak ada analisa akar masalah
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PREDICTIVE MAINTENANCE

• Siklus Monitor terus kondisi mesin Anda setiap waktu,

Operate jika muncul gejala kerusakan, perbaiki sebelum
Condition
Monitoring jatuh rusak !
Perpanjang umur komponen mesin Anda jika
Trend Performance-nya masih baik !

Operate Scheduled
Trend Analyses
repair

Wow …. ini
biangnya !
INCREASED COMPONENT LIFE
EXPECTATION
· Minor problem diperbaiki lebih dini
· Data history memperkuat pembelian equipment
· Down time selalu terjaga minimum
 06

HPMU HPU MAINTENANCE CONCEPT

 07

MAINTENANCE PROCESSES

Cleaning of P2H - Pre use

Machines check

Maintenance
Management Periodical
Maintenance Service
Processes

Service
Programs :
PCR PPM, PPU,
SOS

Midlife
ig ht !
Do it r
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CLEANING OF MACHINES

Kebersihan mesin adalah dasar bagi repair & maintenance quality.

Þ Menghindari kerusakan akibat kotoran, lumpur, debu, dan kontaminasi bahan mudah terbakar.
Þ Meningkatkan ketajaman inspeksi
Þ Meningkatkan kenyamanan kerja maintenance
Þ Meningkatkan kenyamanan operasi

Bersihkan equipment Anda sebelum

scheduled maintenance !
Buatlah jadwal pencucian untuk
equipment Anda !
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P2H = PROGRAM PEMERIKSAAN HARIAN

Pre Use Check oleh Operator

• Menjamin bahwa mesin benar-benar siap Gunakan segala sumber untuk
memperoleh informasi kondisi
operasi
equipment Anda !
• Mengetahui ketidaknormalan mesin lebih dini
Libatkan pengguna equipment
• Mengetahui user’s opinion tentang kondisi Anda dalam maintenance
mesin Cek panel business !
cabin Cek ASO

Inspect kondisi
Cek udara umum
bertekanan

Cek battery

Cek kebocoran
Cek ban /
undercarriage Cek brake
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PERIODICAL SERVICE
• Maintenance rutin dengan dasar interval 250 , 500 , 750 , 1000 , 2000 , 6000 operating hours
• Mencegah breakdown unscheduled akibat penurunan normal performance oil dan parts
• Mendeteksi kerusakan lebih dini

Scheduled
backlog repair Change oil

Greasing

Change filter

General check & Change corrossion

adjustment resistor

Change water Change air cleaner

coolant
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MIDLIFE
• Rebuild/replacement rutin atas komponen kecil / asesoris dengan dasar setengah standar
umur komponen besar (6000 – 7000 operating hrs )
• Mencegah breakdown unscheduled akibat penurunan normal performance komponen kecil.

Midlife Alternator

Midlife Starting Midlife Compressor

Motor

Midlife
Turbocharge

Midlife
Midlife nozzle Waterpump
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PCR / OVERHOUL COMPONENT

• Rebuild/replacement komponen besar secara rutin berdasarkan life time komponen.
– Engine 14000 hrs
– Transmission 12000 hrs
– Differential 14000 hrs, dst
• Mencegah unscheduled breakdown akibat penurunan normal performance komponen besar.

Ovh
Ovh Engine Transmission/PTO

Ovh Pumps

Ovh Hydraulic Ovh Electric

cylinder Wire

Ovh Ovh Final

undercarriage Drive
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PPM = PROGRAM PEMERIKSAAN MESIN

• Machine Condition Monitoring

• Inspeksi, pengukuran, dan adjustment mesin secara rutin
berdasarkan interval 1000 operating hours
• Memprediksi gejala kerusakan, memprediksi umur tersisa,
menyusun jadwal perbaikan.

Test & adjust engine Test & adjust hydraulic

performance performance
• Compile data
pengukuran
Test & adjust pump
Inspect noise performance • Analisa trend
problem dan
performance
Inspect visually,
detect crack Inspect thermally • Prediksi lifetime
• Schedule-kan
Test & adjust transmission/ PTO perbaikan
Test & adjust electric
performance performance
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PPU = PROGRAM PEMERIKSAAN UNDERCARRIAGE

• Undercarriage Condition Monitoring
• Inspeksi, pengukuran, dan adjustment komponen undercarriage secara rutin berdasarkan interval
500 opr hrs (high travel crawler) atau 2000 opr hrs (low travel crawler)
• Memprediksi gejala kerusakan, memprediksi
umur tersisa, menyusun jadwal perbaikan.

Adjust track Ukur

tension keausan link

Ukur keausan Ukur keausan pin • Compile data

teeht sprocket & bushing link
pengukuran
• Analisa trend
Ukur keausan Ukur keausan keausan
rollers shoe grouser
• Prediksi lifetime
• Schedule-kan
Check modus Cek comp. free
perbaikan
keausan movement
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SOS = SCHEDULE OIL SAMPLING

• Oil Lub Condition Monitoring

­ Wear metal analyses
­ Contamination analyses (metal, water, fuel, dirt)
­ Additive deterioration analyses
­ Viscosity
­ Fuel soot GEAR
OIL

ENGINE OIL
• Oil lub condition analyses secara rutin berdasarkan interval :
­ 250 opr hrs (engine oil)
­ 1000 opr hrs (hydraulic oil, gear oil)

• Memprediksi gejala kerusakan, memprediksi umur tersisa, menyusun

jadwal perbaikan.
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IR ON ( F e )
80

60

Ppm
40

20

0
4931 9984 9757 10250 0 0 0 0
Ho ur M e t e r

WEAR METAL VISCOSITAS

Iron : Apa yg menyebabkan Viscosity berubah ?
Sumber keausan : Piston, ring, cylinder, gear, block,
head, cam, roller bearing, race. Viscosity naik :
­Oil teroksidasi
Chrome : ­Foaming/Pump Cavitation
Various plating, liner, ring, some shaft gears. ­Emulsi dengan air
­Jelaga atau kontaminasi padat
Molybdenum :
Ring plating, alloy ( juga oil additive, off shelf Viscosity turun :
supplement )
­Fuel or kontaminasi terlarut
Aluminum : ­Refrigerant
Piston, bushing, thrust, block, blower, cooler cores ­Salah pengisian atau penambahan oil
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MAINTENANCE MANAGEMENT
• Maintenance Planning &
• Maintenance Organization & Information Improvement Setup
Setup
Machine’s
P la n t D e p t. H e ad hourmeter

S u p e rv is o r M a in ten a n ce
P la n n er Data Calculate & Process it !

G ro up L ea d er G ro up L ea d er MIMS

W o rk g ro up W o rk g ro up
M e c h a n ics M e c h a n ics • Average
Working Hour
• Maintenance Support Setup (Part, Komponen, • Maintenance
Tool, Facility) Schedule
– Inventory • Parts
– Vendor/Consignment Support process
– Tools & Facility investment • Manhour
calculation
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Setup target maintenance yang

balance antara Availability
Optimum Reliable required dengan Cost spent !
AVAILABILITY COST

Rebuild

Cost
Availability
Optimum
Cost
Availability

Point Rebuild SCRAP !

1st 2n 3rd, …dst

d
Life hours Life hours
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MIMS = The Maintenance Information Management Tool

MIMS
process MIMS
maintenanc process
Machine e work part
operation order purchase
MIMS MIMS Maintenance
Input opr. process process execution
hours maintenanc APL order
e schedule MIMS
MIMS
process MIMS Processing machine history :
average • Failure history
working • Repair/Maintenance hystory
hours
• Component Tracing

Data support for • R/M duration

improvement • R/M manhours
program • R/M Costing
• Oil/fuel consumption
Data support for • Availability, MTBF, etc
effective decision
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IMPROVEMENT PROGRAM
• Pit Stop Servicing
­ Fuel service, Greasing & oil service, Routine check service at pit stop station
­ Purpose : Reduce idle time

• Backlog Management
­ Potential failure execution during periodic service time
­ Purpose : Reduce unscheduled breakdown

• Oil life and component life extend

­ Supported with oil filtering improvement, PAP& PPM condition monitoring
­ Purpose : Reduce material cost, man hour, and downtime
HYD
OIL

• Modification ENGINE OIL

­ Larger coal bucket, coal vessel, fuel tank

­ Auto lube , etc.
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