Usulan Perbaikan Sistem Perawatan Mesin Filling Menggunakan Metode Reliability Centered Maintenance (RCM) pada PT Pabrik Es Siantar

Abstract

In facing increasingly competitive competition, the food and beverage industry is trying to optimize the resources used such as people, machines, capital, methods and materials. Apart from humans, machines are the most important resource in maintaining product quality. The problem that occurs at PT Perusahaan Es Siantar is the high frequency of machine breakdowns because the company has established a corrective maintenance system where machines are repaired after damage occurs, resulting in high maintenance costs. The high frequency of machine breakdowns causes the continuity of the production process to be disrupted. The aim of this research is to determine the distribution of damage patterns to critical machine components on filling machines so that we can determine the intervals for damage and repair of machine components in order to produce a better preventive machine maintenance schedule, as well as determine an efficient estimate of machine repair costs. Therefore, it is necessary to improve planning for machine maintenance and calculation of maintenance costs using the Reliability Centered Maintenance (RCM) method so that it is able to produce products with the same and perfect quality. The results of this research show that the critical components that cause machine damage are the Filling Nozzle and Electromagnetic Capping Heads with a total of 39 damage in the period March 2023 to February 2024. The proposed replacement schedule for the Filling Nozzle component requires a time interval of 21 days and the Electromagnetic component Capping Heads with a required time interval of 45 days. Based on the results of cost calculations, the cost of failure for engine maintenance is IDR 8,105,667,679, while the cost of preventive engine maintenance is IDR 6,234,296,952. This shows that companies can save costs of IDR 1,398,583,848 or around 17% of the cost of failure if they carry out preventive machine maintenance