Penentuan Strategi Pemeliharaan Menggunakan Pendekatan Reliability Centered Maintenance II Pada Sistem Conveyor Perusahaan Industri Pupuk

Noviliana, Almas (2026) Penentuan Strategi Pemeliharaan Menggunakan Pendekatan Reliability Centered Maintenance II Pada Sistem Conveyor Perusahaan Industri Pupuk. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Sistem conveyor 21-X-118 merupakan infrastruktur kritis pada PT. XYZ, produsen pupuk urea terbesar di Indonesia, yang berfungsi sebagai titik konvergensi tunggal dari Pabrik 4 dan Pabrik 5 menuju Urea Bulk Storage. Sebagai jalur kritis tanpa redundansi yang beroperasi kontinu, kegagalan pada sistem ini berpotensi menimbulkan kerugian finansial mencapai Rp15 miliar per hari. Permasalahan utama terletak pada jadwal pemeliharaan eksisting yang masih disusun secara generik berdasarkan disiplin pelaksana, sehingga belum mempertimbangkan karakteristik kegagalan spesifik dan profil keandalan tiap komponen. Penelitian ini bertujuan menentukan strategi dan interval pemeliharaan yang tepat menggunakan pendekatan Reliability Centered Maintenance II yang diintegrasikan dengan analisis keandalan kuantitatif. Analisis diawali dengan identifikasi struktur fungsi melalui System Breakdown Structure pada lima subsistem pembentuk fungsi utama (belt, roller, pulley, motor, dan gearbox) serta satu subsistem protektif (safety device) yang menghasilkan 35 mode kegagalan. Evaluasi konsekuensi dilakukan menggunakan hierarki Hidden, Safety, Environment, dan Operational untuk menentukan aktivitas pemeliharaan yang optimal. Data histori work order SAP periode 2023–2025 diolah menggunakan ReliaSoft Weibull++ untuk memvalidasi tugas pemeliharaan berdasarkan parameter Beta (β) yang menunjukkan fase wear-out pada mayoritas komponen mekanis. Hasil penelitian menetapkan kombinasi strategi berupa 29 Scheduled On-Condition Task, 4 Scheduled Restoration Task, dan 2 Failure Finding Task. Interval pemeliharaan ditentukan berdasarkan fungsi dan karakteristik kegagalan masing-masing komponen. Interval Scheduled On-Condition Task yang dihasilkan berkisar antara 15 hari pada gearbox hingga 94 hari pada belt, sedangkan Scheduled Restoration Task direkomendasikan setiap 17 hingga 41 hari. Sementara itu, Failure Finding Task pada safety device ditetapkan setiap 165 hari. Penentuan interval yang sesuai dengan karakteristik setiap komponen tersebut diharapkan dapat mengurangi risiko unplanned downtime sekaligus menjaga ketersediaan sistem pada jalur produksi pupuk nasional.
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The 21-X-118 conveyor system is critical infrastructure at PT. XYZ, a major Indonesian urea fertilizer producer, serving as the single convergence point from Plant 4 and Plant 5 to the Urea Bulk Storage. Operating continuously along a critical path without redundancy, failure of this system may result in financial losses of up to IDR 15 billion per day. The main issue lies in the existing maintenance schedule, which remains generically structured by executing discipline rather than each component's specific failure characteristics. This study determines an appropriate maintenance strategy and interval using Reliability Centered Maintenance II (RCM II) integrated with quantitative reliability analysis. The analysis begins by identifying the functional structure through a System Breakdown Structure, covering five subsystems that form the main function (belt, roller, pulley, motor, and gearbox) and one protective subsystem (safety device), yielding 35 failure modes. Consequences were evaluated using the Hidden, Safety, Environmental, and Operational (H-S-E-O) hierarchy to determine the optimal maintenance activities. Historical SAP work order data from 2023–2025 were analyzed using ReliaSoft Weibull++ to validate the selected maintenance tasks based on the shape parameter (β), which indicates a wear-out phase for most mechanical components. The results establish 29 Scheduled On-Condition Tasks, 4 Scheduled Restoration Tasks, and 2 Failure Finding Tasks. Maintenance intervals were determined according to each component's function and failure characteristics. The Scheduled On-Condition Task intervals range from 15 days for the gearbox to 94 days for the belt, while Scheduled Restoration Tasks are recommended every 17 to 41 days. In addition, the Failure Finding Task for the safety device is scheduled every 165 days. Aligning maintenance intervals with the characteristics of each component is expected to reduce unplanned downtime and maintain system availability along the national fertilizer production line.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Sistem Conveyor, Reliability Centered Maintenance II (RCM II), Strategi Pemeliharaan, Interval Pemeliharaan. Conveyor, Reliability Centered Maintenance II (RCM II), Maintenance Strategy, Maintenance Interval.
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:	Almas Noviliana
Date Deposited:	30 Jul 2026 08:38
Last Modified:	30 Jul 2026 08:38
URI:	http://repository.its.ac.id/id/eprint/140065

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