Penerapan Preventive Maintenance dengan Model Age Replacement pada Tertiary Crusher di PT ABC

Egidio, Daniel (2025) Penerapan Preventive Maintenance dengan Model Age Replacement pada Tertiary Crusher di PT ABC. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT ABC merupakan perusahaan yang bergerak pada bidang tambang khususnya tembaga dan emas. Produksi bermula dari ore berupa batu tambang mentah yang diolah menjadi konsentrat melalui mesin-mesin produksi. Pemeliharaan mesin yang efektif menjadi salah satu kunci utama terjaganya kontinuitas produksi perusahaan. Pada Tugas Akhir ini ditinjau pada area concentrator 1 sebagai area tertua yang telah berdiri sejak tahun 1972. Berdasarkan area amatan tersebut, mesin crusher 8 (CR 8) bagian tertiary crusher menjadi mesin dengan downtime tertinggi. Menurut data historis kegagalan, CR 8 mencapai 30,000 kali downtime sejak tahun 2021 hingga 2024. Penerapan pemeliharaan area tertiary crusher saat ini menerapkan Condition-Based Monitoring (CBM) pada komponen repairable dan preventive pada komponen non-repairable atau wear part. Tingkat downtime CR 8 menghasilkan availabilitas sebesar 74%. Selain CR 8 terdapat unit crusher lainnya seperti CR 3, CR 4, CR 5, CR 7, CR 9, CR 10, dan CR 11. Kegiatan downtime secara langsung mempengaruhi production lost dengan rate per ton sebesar 124.56 USD. Berdasarkan availabilitas CR 8, production lost didapatkan sebesar 3,497,02 USD dalam 1 tahun. Pendekatan preventive maintenance pada Tugas Akhir diterapkan model age replacement untuk critical wear parts yang didapatkan melalui metode Fault Tree Analysis (FTA) dan Minimal Cut Sets (MCS). Penggunaan age replacement memiliki keunggulan dalam optimasi penjadwalan, meminimalkan downtime, serta penghematan biaya dari pengurangan production lost. Hasil pergantian optimal komponen akan dikelompokan untuk mengurangi biaya dan downtime akibat pergantian. Hasil grouping pada critical wear parts mendapatkan penurunan biaya sebesar 40.03 USD dalam interval 36 hari. Peningkatan availabilitasnya sebesar 5% dibandingkan kondisi eksisting melalui penurunan downtime sebesar 427 jam setiap tahun. Selain itu, production lost yang menurun sebesar 128,083.11 ton setiap tahun atau setara 15,954,230.88 USD. Dengan demikian, model age replacement dapat menjadi salah satu metode preventive maintenance yang efektif dalam meminimalkan downtime dan production lost pada CR 8 di PT ABC.
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PT ABC is a company engaged in the mining sector, specifically in copper and gold. Production begins with raw ore in the form of unprocessed mining rock, which is then processed into concentrate through production machinery. Effective machine maintenance is one of the key factors in ensuring the continuity of the company's production. This Final Project focuses on Concentrator 1, the oldest area, which has been in operation since 1972. Based on observations in this area, Crusher 8 (CR 8) in the tertiary crusher section has the highest downtime. According to historical failure data, CR 8 has experienced 30,000 instances of downtime from 2021 to 2024. The current maintenance approach for the tertiary crusher area applies Condition-Based Monitoring (CBM) for repairable components and preventive maintenance for non-repairable components or wear parts. The downtime level of CR 8 results in an availability rate of 74%. In addition to CR 8, there are other crusher units such as CR 3, CR 4, CR 5, CR 7, CR 9, CR 10, and CR 11. Downtime activities directly affect production loss at 124.56 USD per ton. Based on CR 8's availability, the production loss amounts to 3,497.02 USD annually. The preventive maintenance approach in this Final Project applies an age replacement model for critical wear parts, determined using the Fault Tree Analysis (FTA) and Minimal Cut Sets (MCS) methods. The use of age replacement offers advantages in optimizing scheduling, minimizing downtime, and reducing costs by lowering production losses. The optimal replacement of components is grouped to reduce costs and downtime associated with replacement. The grouping results for critical wear parts achieve a cost reduction of 40.03 USD within a 36-day interval. Availability is increased by 5% compared to the existing condition through a downtime reduction of 427 hours per year. Additionally,
production loss is reduced by 128,083.11 tons per year, equivalent to 15,954,230.88 USD. Thus, the age replacement model can be an effective preventive maintenance method for minimizing downtime and production loss in CR 8 at PT ABC.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Preventive Maintenance, Age Replacement, Cone Crusher, Production Lost, Critical Wear Parts
Subjects:	T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Daniel Egidio
Date Deposited:	05 Feb 2025 03:30
Last Modified:	05 Feb 2025 03:33
URI:	http://repository.its.ac.id/id/eprint/118198

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