Chasanah, Anggraita Nur (2026) Pengembangan Framework Proactive-Predictive Maintenance Electrical Submersible Pump (ESP) Berbasis Lean-FMEA dan American Petroleum Institute (API) Q2 Untuk Peningkatan Produktivitas. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Dalam operasional minyak dan gas, keandalan Electrical Submersible Pump (ESP) berperan penting dalam menjaga kontinuitas produksi dan kualitas layanan pemeliharaan. Pada kasus ini perusahaan telah memperoleh sertifikasi API Q1 pada kegiatan manufaktur dan saat ini sedang mengembangkan sistem manajemen mutu layanan sesuai API Q2, namun proses pemeliharaan ESP masih menghadapi pemborosan (waste) dan risiko yang menyebabkan tingginya waiting time, peningkatan lead time, serta belum optimalnya efektivitas layanan pemeliharaan. Penelitian ini bertujuan menyusun framework proactive–predictive maintenance pada ESP dengan mengintegrasikan Lean Maintenance, Value Stream Mapping (VSM), dan Failure Mode and Effect Analysis (FMEA), serta menyelaraskannya dengan prinsip service quality pada American Petroleum Institute (API) Q2. Penelitian ini menggunakan pendekatan terapan dengan kombinasi data kualitatif dan kuantitatif melalui telaah dokumen teknis, Daily Report, Log Record VSD, data produksi, catatan downtime, dan Focus Group Discussion (FGD) dengan praktisi ESP. Hasil Current State VSM menunjukkan bahwa proses pemeliharaan aktual memiliki process time 17 jam 45 menit, waiting time 48 jam, dan lead time 65 jam 45 menit. Waste dominan ditemukan pada keterlambatan data, salah klasifikasi awal gangguan, inspeksi surface equipment yang belum seragam, approval delay, spare part waiting, potensi rework, validasi, dan dokumentasi close-out. Analisis reliabilitas menunjukkan total downtime baseline sebesar 169,08 jam, MTBF 253,56 jam/event, MTTR 24,15 jam/event, dan availability 91,31%. Hasil FMEA menunjukkan risiko prioritas tertinggi pada gas locking/no-flow condition dengan RPN 420, diikuti data operasi tidak lengkap, checklist inspeksi surface tidak standar, rework/failure berulang, dan mechanical downhole problem. Berdasarkan integrasi VSM dan FMEA, penelitian ini merancang Future State VSM dengan sembilan tahapan dan lima Risk Control Point (RC), yaitu early warning parameter kritis, FMEA trigger S-O-D/RPN, minimum data set, critical spare part berbasis RPN, serta validasi stabilitas dan pembaruan FMEA. Rancangan ini menghasilkan target process time 12 jam 25 menit, waiting time 11 jam 30 menit, dan lead time 23 jam 55 menit, dengan estimasi penurunan lead time ±63,6% dan waiting time ±76,0%. Framework yang dihasilkan memberikan dasar pengendalian risiko, standardisasi proses, traceability, dan pembaruan berkelanjutan yang lebih terukur serta selaras dengan kebutuhan API Q2.
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In oil and gas operations, the reliability of Electrical Submersible Pumps (ESP) plays an important role in maintaining production continuity and the quality of maintenance services. In this case, the company has obtained API Spec Q1 certification for its manufacturing operations and is currently implementing an API Spec Q2-compliant service quality management system. However, the ESP maintenance process still experiences waste and operational risks, resulting in prolonged waiting time, extended lead time, and suboptimal maintenance service effectiveness. This study aims to develop a proactive–predictive maintenance framework for ESPs by integrating Lean Maintenance, Value Stream Mapping (VSM), and Failure Mode and Effect Analysis (FMEA), while aligning the framework with the service quality principles of the American Petroleum Institute (API) Q2. This study applies an applied research approach using both qualitative and quantitative data obtained from technical document reviews, Daily Reports, VSD Log Records, production data, downtime records, and Focus Group Discussions (FGDs) with ESP practitioners. The Current State VSM results show that the actual maintenance process has a process time of 17 hours and 45 minutes, a waiting time of 48 hours, and a lead time of 65 hours and 45 minutes. The dominant wastes identified include data delays, incorrect initial failure classification, non-standardized surface equipment inspection, approval delays, spare part waiting, potential rework, validation delays, and close-out documentation issues. The reliability analysis shows a total baseline downtime of 169.08 hours, an MTBF of 253.56 hours/event, an MTTR of 24.15 hours/event, and an availability of 91.31%. The FMEA results indicate that the highest priority risk is gas locking/no-flow condition, with an RPN of 420, followed by incomplete operational data, non-standardized surface inspection checklists, repeated rework/failure, and mechanical downhole problems. Based on the integration of VSM and FMEA, this study develops a Future State VSM consisting of nine stages and five Risk Control Points (RCs): critical parameter early warning, FMEA trigger based on S-O-D/RPN, minimum data set, RPN-based critical spare parts, and stability validation with FMEA updates. The proposed design sets a target process time of 12 hours and 25 minutes, a waiting time of 11 hours and 30 minutes, and a lead time of 23 hours and 55 minutes, with an estimated lead time reduction of approximately 63.6% and a waiting time reduction of approximately 76.0%. The resulting framework provides a structured basis for risk control.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Electrical Submersible Pump, Proactive–Predictive Maintenance, Lean Maintenance, Failure Mode and Effect Analysis, API Q2 |
| Subjects: | T Technology > TS Manufactures > TS173 Reliability of industrial products |
| Divisions: | Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT) |
| Depositing User: | Anggraita Nur Chasanah |
| Date Deposited: | 04 Aug 2026 04:25 |
| Last Modified: | 04 Aug 2026 04:25 |
| URI: | http://repository.its.ac.id/id/eprint/142565 |
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