Sukaton, Afrah Althafahillah (2025) Laporan Magang Industri Analisa Maintenance High Pressure Pump Mengunakan Metode FMEA Pada Proses Water Treatment Plant Di PT. Surabaya Industrial Estate Rungkut (SIER). Project Report. [s.n.]. (Unpublished)
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Abstract
PT Surabaya Industrial Estate Rungkut (SIER) mengoperasikan High Pressure Pump pada proses Water Treatment Plant untuk mendukung kebutuhan air bersih kawasan industri. Berdasarkan data maintenance perusahaan periode Januari–Juni 2025, tercatat total 24 kejadian kerusakan/pergantian komponen, dengan frekuensi tertinggi pada komponen Bearing (9 kali, aus), Mechanical Seal (4 kali, kebocoran), dan Baut (4 kali, longgar). Tingginya frekuensi kerusakan ini mengindikasikan belum optimalnya program preventive maintenance pada pompa tersebut. Laporan ini bertujuan menganalisis akar penyebab kerusakan komponen High Pressure Pump menggunakan Fishbone Diagram dan mengevaluasi tingkat kekritisan kegagalan menggunakan metode Failure Mode and Effect Analysis (FMEA). Analisis Fishbone Diagram mengidentifikasi tiga faktor utama penyebab kerusakan, yaitu faktor Man (mekanik tidak mengikuti manual book), Machine (kerusakan mechanical seal, baut, dan bearing), dan Methode (belum adanya preventive maintenance yang terstruktur). Hasil perhitungan FMEA berdasarkan nilai Severity (S), Occurrence (O), dan Detection (D) menunjukkan tiga komponen kritis dengan nilai Risk Priority Number (RPN) tertinggi, yaitu Bearing (RPN 576), Mechanical Seal (RPN 504), dan Baut (RPN 448). Berdasarkan hasil tersebut, diusulkan tindakan preventive maintenance berupa penerapan jadwal pelumasan bearing sesuai spesifikasi, pemantauan suhu dan tekanan pada mechanical seal, penggunaan lock washer pada baut, pelatihan teknisi, serta penyusunan form maintenance sebagai data aktual guna menurunkan frekuensi kerusakan komponen High Pressure Pump.
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PT Surabaya Industrial Estate Rungkut (SIER) operates a High Pressure Pump within its Water Treatment Plant process to supply clean water for the industrial estate. Company maintenance data from January to June 2025 recorded a total of 24 component failure and replacement events, with the highest frequencies occurring in the Bearing (9 times, wear), Mechanical Seal (4 times, leakage), and Bolt (4 times, loosening) components. This high failure frequency indicates that the pump's preventive maintenance program has not yet been optimal. This report aims to analyze the root causes of High Pressure Pump component failures using a Fishbone Diagram and to evaluate failure criticality using the Failure Mode and Effect Analysis (FMEA) method. The Fishbone Diagram analysis identified three main causal factors: Man (technicians not following the manual book), Machine (damage to the mechanical seal, bolts, and bearing), and Method (absence of a structured preventive maintenance program). FMEA calculations based on Severity (S), Occurrence (O), and Detection (D) scores identified three critical components with the highest Risk Priority Number (RPN): Bearing (RPN 576), Mechanical Seal (RPN 504), and Bolt (RPN 448). Based on these findings, preventive maintenance actions are proposed, including scheduled bearing lubrication per specification, temperature and pressure monitoring of the mechanical seal, use of lock washers on bolts, technician training, and the development of maintenance forms as actual operational records to reduce the failure frequency of the High Pressure Pump.
| Item Type: | Monograph (Project Report) |
|---|---|
| Uncontrolled Keywords: | High Pressure Pump, Fishbone Diagram, FMEA, Risk Priority Number, preventive maintenance, High Pressure Pump, Fishbone Diagram, FMEA, Risk Priority Number, preventive maintenance |
| Subjects: | T Technology > TJ Mechanical engineering and machinery T Technology > TJ Mechanical engineering and machinery > TJ903 Pumping machinery. T Technology > TJ Mechanical engineering and machinery > TJ919 Centrifugal pumps--Design and construction. |
| Divisions: | Faculty of Vocational > Mechanical Industrial Engineering (D4) |
| Depositing User: | Afrah Althafahillah Sukaton |
| Date Deposited: | 30 Jul 2026 01:12 |
| Last Modified: | 30 Jul 2026 01:12 |
| URI: | http://repository.its.ac.id/id/eprint/139491 |
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