Design of remote temperature monitoring system on automatic filling R125 Shinva machine using LM35 sensor and Arduino Uno microcontroller

This paper proposed the design of a remote temperature monitoring system of R125 Shinva's automatic filling machine. The R125 Shinva’s automatic filling machine is one of the machines on SF company which main function is fulfilling the infusion liquid into the infusion packaging, this infusion liquid is mainly used for the human medical treatment. Based on the failure history data, this machine has the highest downtime among the others and one of the fatal failures is caused by the overheating of the heating element in the infusion liquid bag's transfer system. Using the proposed design, the temperature of the heating element can be monitored in real-time condition and also giving notification to the maintenance team for the next maintenance action. With the power of cloud-based technology, the monitoring system not only on-site monitoring but also can use a web server monitoring, and mobile monitoring system

Design of remote temperature monitoring system on automatic filling R125 Shinva machine using LM35 sensor and Arduino Uno microcontroller

This paper proposed the design of a remote temperature monitoring system of R125 Shinva's automatic filling machine. The R125 Shinva’s automatic filling machine is one of the machines on SF company which main function is fulfilling the infusion liquid into the infusion packaging, this infusion liquid is mainly used for the human medical treatment. Based on the failure history data, this machine has the highest downtime among the others and one of the fatal failures is caused by the overheating of the heating element in the infusion liquid bag's transfer system. Using the proposed design, the temperature of the heating element can be monitored in real-time condition and also giving notification to the maintenance team for the next maintenance action. With the power of cloud-based technology, the monitoring system not only on-site monitoring but also can use a web server monitoring, and mobile monitoring system

Maintenance System of Universal Goss Printing Machine based on failure data using RCM and RCS method

Over time a machine will get experience a decrease in reliability, causing the engine to be damaged at the time of operation, thus disrupting the production line. To maintain a machine remains reliable then a good maintenance system is required. In this research, we will use Reliability Centered Maintenance (RCM) and Reliability Centered Spare (RCS) analysis on the critical system of Goss Universal printing machine based on engine failure data. The result of RCM analysis obtained the optimal preventive maintenance schedule and the type of treatment, while based on the RCS analysis obtained spare part needs following the maintenance schedule. With the result of this analysis, is expected where the machine will keep good and will continue to operate without a sudden breakdown under the production schedule's need. Based on RCM analysis for each critical subsystem obtained interval preventive maintenance for transfer roller 127.60 hours, Ink fountain roller 24.45 hours, ink form roller 29.23 hours respectively, and the wash-up device is no scheduled maintenance. For spare parts inventory strategies the result using RCS method are: transfer roller104 units, ink fountain roller requires 32 units, ink form roller 36 units and are holding spare policy required, and a wash-up device no holding spare parts. Keywords— Failure data, Maintenance System, RCM, RC

Designing The Estimation of The Need for Spare Parts and Inventory Policy on The D32 CP8 Compressor Machine

Based on damage data owned by PT XYZ, the compressor engine that has a history of high damage is the D32 CP8 Compressor Engine. Critical components of the D32 CP 8 Compressor are determined using a risk matrix. The critical components selected from the D32 CP8 Compressor Engine are Screw Motor, Refrigerant Air Cooler, and Cylinder Bearing Oil Cooler. This study uses the Reliability Centered Spares (RCS), Min-Max Stock, and Reorder Point (ROP) methods. The data collection and processing results obtained the need for critical components in the next 1 year based on the MTTF critical component data. These calculations show that the value of the required spare parts for the Motor Screw, Refrigerant Air Conditioner, and Cylinder Bearing Oil Cooler in a year is 8 components. The minimum Stock of the Screw Motor is 3 components, the maximum stock is 8 components, ReOrder Point point is 4 components. The minimum stock of 4 component air coolers, maximum stock of 7 components, ReOrder Point when 3 components. The minimum stock of a Cylindrical Bearing Oil Cooler is 2 components, the maximum stock is 6 components, and the ReOrder Point is when there are 2 components.Berdasarkan data kerusakan yang dimiliki PT XYZ, mesin kompresor yang memiliki riwayat kerusakan tinggi adalah Mesin Kompresor D32 CP8. Komponen kritis dari Kompresor D32 CP 8 ditentukan menggunakan matriks risiko. Komponen kritis yang dipilih dari Mesin Kompresor D32 CP8 adalah Motor Sekrup, Pendingin Udara Refrigeran, dan Pendingin Oli Bantalan Silinder. Penelitian ini menggunakan metode Reliability Centered Spares (RCS), Min-Max Stock, dan Reorder Point (ROP). Hasil pendataan dan pengolahan yang dilakukan didapatkan kebutuhan komponen kritis dalam 1 tahun ke depan berdasarkan data komponen kritis MTTF. Dari perhitungan tersebut diperoleh nilai kebutuhan suku cadang Motor Sekrup, Pendingin Udara Refrigeran, dan Pendingin Oli Bantalan Silinder dalam setahun adalah 8 komponen. Stock minimum Screw Motor adalah 3 komponen, stock maksimum 8 komponen, ReOrder Point point bila 4 komponen. Stok minimum pendingin udara pendingin 4 komponen, stok maksimum 7 komponen, titik ReOrder Point ketika 3 komponen. Stok minimum Cylindrical Bearing Oil Cooler adalah 2 komponen, stok maksimum 6 komponen, dan titik ReOrder Point saat 2 komponen

EVALUATION OF PERFORMANE CINCINATI DOUBLE GANTRY F MACHINE USING RELIABILITY, AVAILABILITY, MAINTAINABILITY, AND SAFETY ANALYSIS IN XYZ COMPANY

PT XYZ operate the machine Cincinati Double Gantry F since 1987. However, during the operating there are problems such as failure of the process that affect the performance of the machine so that the impact on the losses of the company, namely a decrease in revenue. Based on the damage data for the month of January 2016 – December 2018, the subsystem Axis and Electrical Panel & Control is a critical subsystem of the results of the risk matrix with the frequency of the highest damage, namely a total of 33 and 21. Therefore, the necessary steps to reduce losses that occur with conducting research to analyze the value of Reliability, Availability, Maintainability and Safety Analysis (RAMS). The results of the RAM by using the modeling of RBD based on the subsystem selected results obtained value of the reliability a subsystem of the Axis is lower than the Electrical Panel & Control. The time required to restore the subsystem Axis to normal range 1 hour (98%) and subsystems of Electrical Panel & Control ranged from 1 h (96%). Based on the evaluation standard IVARA World Class Maintenance Key Performance Indicators with leading indicators and lagging has reached the target of 95%. The results of research on the safety analysis at the time of the time interval of 16 hours a subsystem of the Axis is lower than on Electrical Panel & Control on the level of Safety Integrity Level However at the time of the time interval 80 hours, a subsystem of the Axis does not reach the target SIL according to standard IEC 61508.Keyword: 1 Cincinati Double Gantry F 2 Reliability Availability Maintainability 3 Safety Analysis, Maintenance Key Performance Indicator 4 SIL 5 IEC 6150

IMPLEMENTATION OF MAINTENANCE SCENARIO FOR CRITICAL SUBSYSTEM IN AIRCRAFT ENGINE Case study: NTP CT7 engine

An aircraft company needs to "secure" their aircraft engine for a good maintenance system to keep the optimum engine's performance during the flight. This paper proposed maintenance analysis and scenario for the CT7, the main engine for aircraft at NTP company. A failure data record from four critical components of the CT7 engine is analyzed using Reliability Centered Maintenance (RCM) and Risk Based Maintenance (RBM) methods to obtain the optimum maintenance interval task for the critical subsystem of the CT7 engine and also seeing the risk of maintenance cost of the engine's failure effect.  The RCM analysis result obtained seven scheduled on condition task, six scheduled discard task, and three scheduled restoration task. The interval of the maintenance schedule of each critical component varies according to the function obtained. And based RBM analysis, the risk from system performance loss is got $7.014.841, 90. Meanwhile, the total cost of maintenance interval based on a calculation of optimal time interval got$1.885.612, 82. Keywords— preventive maintenance, reliability-centered maintenance, risk-based maintenance, risk priority number

KEBIJAKAN PERSEDIAAN SUKU CADANG DI PT ABC MENGGUNAKAN METODE RCS (RELIABILITY CENTERED SPARES)

Based on data from the production and maintenance department, the highest downtime happen in JDK machine at ABC company. High downtime caused by spare parts lacking or replacement parts when the machine damaged, it cause the engine stop longer. This study analyze and determine spare part inventory the policy, especially critical components in JDK machine. Reliability Centered Spare (RCS) method used in this study, this method essentially determines the optimal spare parts policy for a certain period. The result of research with RCS method shows that the spare parts inventory policy for all critical components of JDK machine in one year ahead by storing or stocking the following amount: packing valve: 469 pieces; teflon: 134 pieces; bearing pump: 10 pieces; mechanical seal: 26 pieces; motor pump: 10 pieces; packing pump: 141 pieces; motor driving reel: 9 pieces; bearing driving reel: 45 pieces; mechanical seal driving reel: 163 pieces; packing heat exchanger: 70 pieces; site glass: 29 pieces; and pressure gauge: 7 pieces

KNOWLEDGE CONVERSION PERANCANGAN INSTRUKSI KERJA KEGIATAN PREVENTIVE MAINTENANCE MESIN HAAS CNC MILLING DENGAN METODE SECI

Nowadays to gain a competitive advantage in an organization, knowledge becomes important as an asset that must be managed. The experience possessed by humans is tacit and sometimes difficult to extract into a procedure or standard that can be used in an organization. T University is a private university in Indonesia. At the University of T, there is a laboratory that serves as a provider of practical services for students, one of the laboratory is laboratory X. Laboratory X serves to provide an understanding in the Manufacturer process for mass production. Currently, this laboratory consists of 18 assistant labs and one laboratory staff. This laboratory has one Haas CNC Milling used in labwork activity. To keep the machine in optimum condition, good maintenance management of the facility is required especially preventive maintenance, These activities are conducted based on the experience of laboratory staff in handling Haas CNC Milling machine. The problems occurs when the laboratory staff is entering the retirement period. besides that until now there is no standard operation procedure (SOP) developed by the university about how to do preventive maintenance.This research aims to design preventive maintenance work instruction for CNC Milling Haas machine with SECI (Socialization, Externalization, Combination, and Internalization) methods. Best practice in the form of a work instruction is obtained from the process of knowledge conversion from laboratory staff and head of laboratory. From the exploration result, it is known that preventive maintenance activities for Haas CNC Milling machine consist of spindle cleaning, checking tools, lubrication check and engine coolant, and run test. Brainstorming is done to confirm and select best practices created by both speakers. From the brainstorming result, it is known that the work instructions performed by the laboratory staff are selected by modifying some aspects of checkin

An Autonomous Maintenance Design Based on Overall Resource Effectiveness (ORE) Analysis: A Case Study of Paving Molding Machine

The paving molding machine is one of the machines used to produce black paving at PT XYZ. Based on the historical data from the engineering maintenance department, this machine has the highest breakdown frequency which affected the low performance and productivity of the machine. To solve this problem, the effectiveness of the paving molding machine was analyzed using overall resource effectiveness (ORE) methods. ORE aims to analyze machine indicators, consisting of readiness, availability of the facility, changeover efficiency, availability of material, availability of manpower, performance efficiency, and quality rate. The ORE analyzed result shows that values of performance efficiency of paving molding machine were 64.54% and still below the standards of the ORE. To increase the ORE, a design of autonomous maintenance (AM) was proposed. The proposed design means the operator is given the responsibility to maintain the basic condition of the machine to minimize the damage of the paving molding machine at PT XYZ. The result of ORE analysis, especially in the performance efficiency, will be an input for the engineering maintenance department to make an AM basic design that can be executed by each of the machine's operators. In general, this research’s novelty is to combine the application of the ORE method with the AM basic design, whereas the AM is one of the pillars of total productive maintenance (TPM)

Proposed Maintenance Policy Design on Paving Molding Machine Using Reliability and Risk Centered Maintenance (RRCM) Method at PT XYZ

PT. XYZ is a company engaged in construction and manufacturing. The company focuses on paving production. Where there is a problem with paving printing machines in carrying out production, there are many productions that do not reach the target or the production process does not run optimally.   The purpose of this study is to find out the performance of paving molding machines, especially in the components that most often experience damage to paving molding machines. Based on historical data on machine damage, a paving molding machine is a machine that has had the highest frequency of damage for 5 years, because this machine operates continuously to meet production targets and paving demand from customers. Reliability and Risk Centered Maintenance (RRCM) methods to be used to analyze a historical engine malfunction. The results obtained in the form of 7 proposed maintenance tasks are 2 scheduled on-condition tasks, 3 scheduled restoration tasks, 2 scheduled waste tasks. In addition, the average maintenance time interval for pillow blocks is 7 months, iron molding is 11 months, and chain is 4 months. The total cost of proposed maintenance is lower than IDR 52,938,750 or 41.7% compared to the existing maintenance cost of PT. XYZ. The development of this research is to increase the application of RCM as a basis for maintaining the balance between preventive maintenance and corrective maintenance while optimizing maintenance costs to improve engine reliability by considering risk factors as an analysis