REDUCING DOWNTIME THROUGH SCHEDULING OF PREVENTIVE MAINTENANCE AND MONITORING SYSTEM USING POWER BI

Abstract

The machine is essential aspect in PT XY's production system as the largest toy car producer. Pad Printing is one area in the toy car production system. This area serves to give a design or motif to the car body. The machine operates 24 hours a day, so it is vital to maintain its performance always to appear prime. Based on data from April 2021 to September 2021, the Pad Printing area experienced 284 downtimes with a duration of 216.97. The high downtime duration is caused by component changes that occur between the preventive maintenance schedule intervals. As a result, PT XY suffered a loss of IDR 694,304,000. The maintenance system is considered less proper and effective to support machine performance. One of the factors is the maintenance schedules which is made based on common sense, not based on machine reliability theory. Moreover, the maintenance checklist is considered too general and there is no monitoring system that helps the process engineer to analyze the performance of the printing pad area. For this reason, this final project is carried out to improve overall system maintenance. Improvements started by enhancing the preventive maintenance schedule based on component reliability, improving the maintenance checklist, improving the database system, and improving the monitoring system with Power BI. Breakdown costs will decrease by more than 100% but maintenance costs will increase drastically. Besides that, system the proposed improvement can increase machine reliability twice from the current system and save the company's expenses up to IDR 4,599,275. Furthermore, he Power BI dashboard was proposed to assist users in monitoring and controlling system maintenance more quickly and easily.