IMPLEMENTATION OF PREVENTIVE MAINTENANCE IN INJECTION MOULDING TO INCREASE MACHINE RELIABILITY IN PT.ASD

Abstract

As a multinational toy company that produces toys to be shipped to many countries, maintenance is very important in a company to keep production process running. PT ASD is currently facing reliability issues in plastic injection molding area where the injection molding machine has a high breakdown record. The objective of this research is to determine the component that contributes the most breakdown machine and propose preventive maintenance scheduling system to increase 80% of the reliability. The research is conducted by processing the Mean Time to Repair (MTTR) and Mean Time between Failure (TBF) data according to probability distribution then calculate the reliability of each component before and after using preventive maintenance system. Based on the research there are 5 critical components that causing the highest breakdown of the machine. The result of this research is the components achieved the reliability to 80%. The components that caused the most of breakdown machine is determined the new maintenance scheduling to reach the proposed reliability with limit switch component with maintenance interval every 9 days, hydraulic motor fan component for every 29 days, hydraulic pump component for every 15 days, manifold solenoid valve component for every 37 days, and component filter element with maintenance interval for every 9 days.