Optimasi Preventive Replacement Komponen Kritis Excavator Komatsu PC2000-8 Untuk Minimasi Downtime di PT XYZ

Soleh, Imam Nur (2026) Optimasi Preventive Replacement Komponen Kritis Excavator Komatsu PC2000-8 Untuk Minimasi Downtime di PT XYZ. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Ketersediaan alat gali-muat menentukan efisiensi operasi tambang terbuka. Pada unit excavator Komatsu PC2000‑8 berfungsi sebagai prime equipment. Gangguan pada komponen kritis berdampak langsung pada downtime, biaya pemeliharaan, dan capaian key performance indicator seperti physical availability (PA), mean time between failure (MTBF) dan mean time to repaire (MTTR). Praktik pemeliharaan pencegahan yang masih dominan mengikuti interval generik pabrikan masih sering menimbulkankegagalan aktual, sehingga diperlukan strategi optimasi interval penggantian preventive replacement berbasis minimasi biaya dan minimasi downtime. Penelitian ini bertujuan menentukan interval preventive replacement yang optimal pada komponen kritis excavator Komatsu PC2000‑8 untuk meminimalkan downtime dan biaya, sekaligus meningkatkan availability Metode yang digunakan adalah pendekatan kuantitatif komparatif-optimasi: identifikasi komponen kritis dengan diagram pareto berbasis frekuensi kejadian dan akumulasi downtime. Analisis dilakukan melalui pemilihan sebaran waktu antar kerusakan menggunakan Software Relyence Weibull untuk mengestimasi parameter distribusi data. Perhitungan keandalan, laju kegagalan, MTBF, pemodelan biaya preventive vs corrective replacement meliputi, suku cadang, tenaga kerja, peralatan pendukung, lost production/implikasi kontraktual dan optimasi kebijakan Age Replacement untuk memperoleh interval penggantian yang meminimalkan biaya rata‑rata per satuan waktu dengan batasan kinerja availability. Hasil penelitian menunjukkan bahwa interval preventive replacement yang optimal berdasarkan minimasi biaya ditetapkan sebagai berikut: cylinder boom 11.545 jam, turbocharger 16.820 jam, water pump 7.366 jam, final drive 20.026 jam, dan radiator 19.624 jam. Sementara interval optimal berdasarkan minimasi downtime adalah cylinder boom 10.690 jam, turbocharger 17.555 jam, water pump 8.618 jam, final drive 19.643 jam, dan radiator 19.664 jam. Penerapan interval optimal ini mampu meningkatkan reliability dan availability komponen kritis. Dengan demikian, penelitian ini menghasilkan interval preventive replacement optimal untuk komponen kritis sebagai dasar pemeliharaan, sehingga meningkatkan efisiensi dan mengurangi downtime.
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The availability of primary loading equipment determines the efficiency of open‑pit mining operations. For the Komatsu PC2000‑8 excavator, which functions as prime equipment, failures of critical components directly impact downtime, maintenance costs, and key performance indicators such as Physical Availability (PA), Mean Time Between Failures (MTBF), and Mean Time to Repair (MTTR). Preventive‑maintenance practices that still largely follow generic OEM intervals often result in actual failures, indicating the need for an optimization strategy for preventive‑replacement intervals based on cost and downtime minimization. This study aims to determine optimal preventive‑replacement intervals for the Komatsu PC2000‑8’s critical components to minimize downtime and costs while improving availability.
A The method employed is a quantitative comparative-optimization approach: critical components are identified using a Pareto diagram based on failure frequency and accumulated downtime. Reliability analysis is conducted by selecting the time‑between‑failures distribution using Relyence Weibull software to estimate distribution parameters. Calculations of reliability, hazard rate, MTBF, and cost modeling for preventive versus corrective replacement-including spare parts, labor, supporting equipment, lost production/contractual implications-are performed. An Age‑Replacement policy is then optimized to obtain replacement intervals that minimize the long‑run average cost per unit time under availability performance constraints. The results indicate that the optimal preventive‑replacement intervals based on cost minimization are: Cylinder Boom 11,545 hours, Turbocharger 16,820 hours, Water Pump 7,366 hours, Final Drive 20,026 hours, and Radiator 19,624 hours. Meanwhile, the optimal intervals based on downtime minimization are: Cylinder Boom 10,690 hours, Turbocharger 17,555 hours, Water Pump 8,618 hours, Final Drive 19,643 hours, and Radiator 19,664 hours. Applying these optimal intervals improves the reliability and availability of the critical components. Therefore, this study provides optimal preventive‑replacement intervals for critical components as a basis for maintenance, enhancing operational efficiency and reducing downtime.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Preventive Maintenance, Age Replacement, Keandalan, Downtime, Availability, Excavator. preventive maintenance, Age Replacement, Reliability, Downtime, availability, Excavator
Subjects:	T Technology > TS Manufactures > TS167 Costs, Industrial T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering)
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Imam Nur Soleh
Date Deposited:	17 Jul 2026 07:10
Last Modified:	17 Jul 2026 07:11
URI:	http://repository.its.ac.id/id/eprint/135328

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