Abstract:
As one of the main vital for automotive company, the maintenance of machine is
very vital to be maintained and controlled to prevent any meaningless downtime.
But during January 2015 until November 2018, machine is the highest downtime
contributor for molding line with total downtime 2320.49 hours. Especially for dust
collector machine IDC001 that contribute the highest downtime of the machines. It
is caused by the current preventive maintenance schedule still not considering the
machine reliability. The schedule also cannot represent the actual lifetime of its
critical components which are dust tube, shaft, v-belt, and bearing. Moreover, there
is no any data recorded about the components performance that make the
maintenance team cannot predict the component lifetime accurately. The objectives
of this research are to achieve 80% reliability and to get more data of component
performance by proposing the new preventive maintenance schedule and
continuous monitoring activity. After several failure functions calculation, then the
new preventive maintenance schedule is established. Through the analysis of what
the current maintenance system needs today, there are vibration monitoring and
dust concentration monitoring activities that will be proposed to get more data to
predict the component lifetime in the future. By implementing the proposed
preventive maintenance schedule and continuous monitoring activities, the
maintenance team able to get more data to predict the component lifetime and the
reliability of each component will increase into 80% with total savings IDR
830,645,805.
