PREVENTIVE MAINTENANCE APPROACH TO INCREASE THE RELIABILITY OF SABMAN 4 MACHINE IN RIGID PLASTIC MANUFACTURING COMPANY

Abstract

As the plastic packaging manufacturer that support the Fast Moving Consumer Good (FMCG) Company, PT XYZ Rigid Plastic Manufacturer is required to increase the production capacity to fulfil the high demand. It makes the production machines have to operate continuously that can lead to the damage or failure of the machine. Actually the company already has the preventive maintenance scheduling in order to prevent the failure occurrence. But it still not effective and not consider the reliability of the machine. The reliability needs to be considered in order to ensure the good performance of the machine. According to the maintenance record during 2016 – 2017, Sabman 4 machine contributes the most to the stoppage loses of the machines. Hydraulic hose, seal, cylinder, sensor, and linear bearing are the critical sub component of Sabman 4 machine. The objective of this research is to propose the new preventive maintenance scheduling in order to achieve the 80% of reliability. After several failure function calculation based on the failure data distribution, then the replacement interval is obtained to establish new scheduling. By implementing the proposed system, the reliability will increase by 42% and has a total savings of IDR 36,403,040.