Perencanaan Preventive Maintenance Mesin Rice Polishing Menggunakan Metode Failure Mode Effect and Criticality Analysis (FMECA) dan Reliability Centered Maintenance (RCM)

Abstract

CV. Hariara is a company engaged in the rice processing industry and uses rice polishing machines in its production process. These machines often experience breakdowns, causing production losses. Currently, the company relies on corrective maintenance, which is maintenance performed after the machine breaks down. This approach leads to very high costs due to the need to replace damaged components unexpectedly, resulting in long downtimes and significant financial losses. Additionally, corrective maintenance does not guarantee optimal machine reliability, as failures can occur unpredictably, exacerbating the management of costs and production time. This study aims to design a preventive maintenance system using the Failure Mode Effect and Criticality Analysis (FMECA) and Reliability Centered Maintenance (RCM) methods to improve machine reliability and optimize maintenance costs. Through the FMECA analysis, critical components were identified, namely the bearing with an RPN value of 320 and the belt with an RPN value of 315. The component replacement interval schedule was derived from the MTTF value, with the bearing replacement interval being every 47 days and the belt every 69 days, while routine maintenance for each critical component is performed every 32 days. Based on cost calculations, the cost of failure for machine maintenance is IDR 2,123,390,519, while the cost of preventive maintenance is IDR 1,517,603,389. This shows that the company can save IDR 605,787,131 in cost of failure by implementing preventive maintenance. Furthermore, with the RCM Decision Worksheet analysis, proposed maintenance tasks for each failure mode were obtained, including scheduled restoration tasks, which involve periodic inspections and maintenance actions, and scheduled discard tasks, which involve the regular replacement of components and parts.