Analysis of Preventive Maintenance Actions on Linear Rotary Machines Using the Reliability Centered Maintenance Method

Oct 13, 2025 by sorusgentrification.com 15 views

Analysis of Preventive Maintenance Actions on Linear Rotary Machines Using the Reliability Centered Maintenance Method

Introduction

In the manufacturing industry, the reliability and efficiency of machinery are crucial for maintaining productivity and reducing costs. One of the main challenges faced by companies is the problem of machine damage, which can lead to losses in the form of rejected products and increased maintenance costs. This study aims to determine the optimal scheduled maintenance time and identify the causes of engine damage based on the selected critical components of linear rotary machines used in the production of cooking oil.

Background

PT Palmanco is a company engaged in the production and sales of cooking oil. The company's main challenge is the problem of oil packaging machines that are often damaged, resulting in losses for the company. The high amount of damage causes rejected products and increased maintenance costs. Therefore, this study aims to determine the optimal scheduled maintenance time and identify the causes of engine damage based on the selected critical components.

Methodology

The Reliability Centered Maintenance (RCM) method is applied to identify the failure mode and determine the preventive maintenance task policy in accordance with the failure mode. In this study, the calculation was carried out using the average time to failure (MTTF) and the average time to repair/MTTR) based on the distribution of the engine damage that had been tested. The results showed that the damage interval for the servo thread component was 283.5 hours, blow was 306.5 hours, and straight was 281.57 hours. As for the repair time interval, the results of 60.37 hours were obtained for servo threads, 29.59 hours for blowing, and 37.70 hours for straight.

Results

The proposed maintenance recommendations consist of 2 scheduled recovery tasks and 1 scheduled disposal task. Taking into account the maintenance time obtained, the maintenance time interval was 33.64 days for Servo Screw, 56.53 days for blowing, and 44.57 days for straight. With the proposed maintenance strategy, the total cost required is IDR 416,662,496, which is a savings of 25% compared to the actual costs incurred.

Discussion

The Reliability Centered Maintenance (RCM) method has an advantage in determining appropriate maintenance measures based on risk analysis and failure impact. By mapping the critical components of the machine, the company can focus more on carrying out maintenance on the most vulnerable part of damage. The use of historical data about engine damage is very important in this analysis process. This makes it possible to understand the pattern of damage and predict when the possibility of damage will occur in the future.

Conclusion

The application of the RCM method in the preventive maintenance of cooking oil packaging machines at PT Palmanco not only succeeded in reducing maintenance costs but also increasing the reliability of the engine. This strategy can be a model for other companies that face similar problems in an effort to optimize machine performance and reduce losses due to damage.

Recommendations

Based on the results of this study, the following recommendations are made:

The company should implement the RCM method as a determinant of preventive maintenance strategies to reduce maintenance costs and increase machine reliability.
The company should focus on carrying out maintenance on the most vulnerable part of damage to reduce the risk of machine failure.
The company should use historical data about engine damage to understand the pattern of damage and predict when the possibility of damage will occur in the future.

Limitations

This study has several limitations, including:

The study only focused on the linear rotary machines used in the production of cooking oil.
The study only used historical data about engine damage to understand the pattern of damage.
The study did not consider other factors that may affect machine reliability, such as operator error and environmental factors.

Future Research Directions

Future research should focus on:

Developing a more comprehensive model of machine reliability that takes into account other factors that may affect machine reliability.
Testing the RCM method on other types of machines to determine its effectiveness.
Developing a more efficient and effective maintenance strategy that takes into account the results of this study.

References

[List of references cited in the study]

Appendix

[Appendix containing additional information, such as tables and figures, that support the results of the study]
Frequently Asked Questions (FAQs) About Preventive Maintenance Actions on Linear Rotary Machines Using the Reliability Centered Maintenance Method

Q: What is the Reliability Centered Maintenance (RCM) method?

A: The RCM method is a maintenance strategy that focuses on identifying and addressing the root causes of machine failure. It involves analyzing the failure modes of a machine and determining the most effective maintenance actions to prevent or mitigate those failures.

Q: What are the benefits of using the RCM method?

A: The RCM method offers several benefits, including:

Reduced maintenance costs
Increased machine reliability
Improved productivity
Enhanced safety

Q: How does the RCM method work?

A: The RCM method involves the following steps:

Identify the critical components of a machine
Analyze the failure modes of those components
Determine the most effective maintenance actions to prevent or mitigate those failures
Implement those maintenance actions

Q: What are the key components of the RCM method?

A: The key components of the RCM method include:

Failure modes and effects analysis (FMEA)
Risk analysis
Maintenance task policy
Maintenance schedule

Q: How can the RCM method be applied to linear rotary machines?

A: The RCM method can be applied to linear rotary machines by:

Identifying the critical components of the machine
Analyzing the failure modes of those components
Determining the most effective maintenance actions to prevent or mitigate those failures
Implementing those maintenance actions

Q: What are the advantages of using the RCM method on linear rotary machines?

A: The advantages of using the RCM method on linear rotary machines include:

Reduced maintenance costs
Increased machine reliability
Improved productivity
Enhanced safety

Q: What are the limitations of the RCM method?

A: The limitations of the RCM method include:

Requires significant data and analysis
Can be time-consuming and resource-intensive
May not be effective for all types of machines or industries

Q: How can the RCM method be integrated with other maintenance strategies?

A: The RCM method can be integrated with other maintenance strategies, such as:

Predictive maintenance
Preventive maintenance
Corrective maintenance

Q: What are the future directions for the RCM method?

A: The future directions for the RCM method include:

Developing more advanced and sophisticated analysis tools
Integrating the RCM method with other maintenance strategies
Applying the RCM method to a wider range of industries and machines

Q: How can the RCM method be implemented in a real-world setting?

A: The RCM method can be implemented in a real-world setting by:

Identifying the critical components of a machine
Analyzing the failure modes of those components
Determining the most effective maintenance actions to prevent or mitigate those failures
Implementing those maintenance actions

Q: What are the benefits of implementing the RCM method in a real-world setting?

A: The benefits of implementing the RCM method in a real-world setting include:

Reduced maintenance costs
Increased machine reliability
Improved productivity
Enhanced safety

Q: What are the challenges of implementing the RCM method in a real-world setting?

A: The challenges of implementing the RCM method in a real-world setting include:

Requires significant data and analysis
Can be time-consuming and resource-intensive
May not be effective for all types of machines or industries

Q: How can the RCM method be evaluated and validated?

A: The RCM method can be evaluated and validated by:

Analyzing the effectiveness of the RCM method in reducing maintenance costs and increasing machine reliability
Conducting case studies and pilot projects
Gathering feedback from users and stakeholders

Q: What are the future research directions for the RCM method?

A: The future research directions for the RCM method include:

Developing more advanced and sophisticated analysis tools
Integrating the RCM method with other maintenance strategies
Applying the RCM method to a wider range of industries and machines