STRATEGI PEMELIHARAAN MESIN FILLING UNTUK MEMINIMASI DOWNTIME DENGAN RELIABILITY CENTERED MAINTENANCE II (RCM II) DAN AGE REPLACEMENT (Studi Kasus pada PT Bintang Toedjoe, Jakarta Timur)

KHAIRUNNISA, PUTRI AMANDA (2025) STRATEGI PEMELIHARAAN MESIN FILLING UNTUK MEMINIMASI DOWNTIME DENGAN RELIABILITY CENTERED MAINTENANCE II (RCM II) DAN AGE REPLACEMENT (Studi Kasus pada PT Bintang Toedjoe, Jakarta Timur). Skripsi thesis, UPN Veteran Yogyakarta.

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Abstract

ABSTRAK
Kegiatan perawatan mesin merupakan aspek penting dalam menjamin
kelancaran operasional fasilitas produksi. Proses produksi di PT Bintang Toedjoe
mengalami hambatan akibat kerusakan pada mesin filling merek Ilapak yang
beroperasi dalam 3 shift sehingga meningkatkan risiko kegagalan tak terencana
yang akan mengakibatkan downtime mesin. Selama periode Januari 2024 hingga
Januari 2025, tercatat 752 kejadian kegagalan tak terencana pada 12 unit mesin
dengan total downtime (durasi kegagalan tak terencana) mencapai 1.958,61 jam.
Mesin Ilapak 11 menjadi penyumbang tertinggi dengan 96 kejadian dan durasi
327,83 jam (16,74% dari total durasi downtime 12 mesin filling Ilapak). Meskipun
perusahaan telah menerapkan pemeliharaan berbasis waktu, masih diperlukan
strategi pemeliharaan yang lebih terukur dan berbasis data guna menekan downtime
dan meningkatkan keandalan mesin.
Penelitian ini menerapkan pendekatan Reliability Centered Maintenance II
(RCM II) dan Age Replacement untuk merancang strategi perawatan mesin filling
Ilapak 11. Analisis dilakukan melalui FMEA dan RCM decision worksheet untuk
menentukan jenis tindakan perawatan, sementara metode Age Replacement
digunakan untuk menetapkan interval penggantian komponen secara optimal guna
mengurangi downtime dan menjaga keandalan mesin.
Hasil pengolahan data mengidentifikasi lima komponen mesin filling Ilapak
11 dengan mode kegagalan berbeda yang direkomendasikan untuk tindakan
scheduled discard task. Penerapan strategi pemeliharaan pencegahan berbasis RCM
II dan Age Replacement pada lima komponen tersebut secara keseluruhan berhasil
mengurangi downtime dan meningkatkan keandalan mesin dengan penurunan
downtime sebesar dari 66,02 jam menjadi 37,87 jam (turun 42,64%). Penurunan ini
menunjukkan bahwa strategi penggantian terjadwal mampu mengatasi kegagalan
pada komponen kritikal sehingga mencegah gangguan mendadak yang berdampak
pada keberlangsungan proses produksi.
Kata kunci: Pemeliharaan pencegahan, Reliability Centered Maintenance II, Age
replacement, FMEA, Penggantian komponen terencana.
xiv
Filling Machine Maintenance Strategy to Minimize Downtime with
Reliability Centered Maintenance II (RCM II) And Age Replacement
ABSTRACT
Machine maintenance activities are an important aspect in ensuring the
smooth operation of production facilities. The production process at PT Bintang
Toedjoe experienced obstacles due to damage to the Ilapak filling machine, which
operates in 3 shifts, thereby increasing the risk of unplanned failures that would
result in machine downtime. During the period from January 2024 to January 2025,
there were 752 instances of unplanned failures across 12 machines, resulting in a
total downtime of 1,958.61 hours. The Ilapak 11 machine contributed the highest
number of incidents with 96 occurrences and a duration of 327.83 hours (16.74%
of the total downtime duration of the 12 Ilapak filling machines). Although the
company has implemented time-based maintenance, a more measurable and data
driven maintenance strategy is still needed to reduce downtime and improve
machine reliability.
This study applied the Reliability Centered Maintenance II (RCM II) and
Age Replacement approaches to design a maintenance strategy for the Ilapak 11
filling machine. Analysis was conducted using FMEA and RCM decision
worksheets to determine the type of maintenance actions, while the Age
Replacement method was used to establish optimal component replacement
intervals to reduce downtime and maintain machine reliability.
Data processing identified five components of the Ilapak 11 filling machine
with different failure modes that were recommended for scheduled discard tasks.
The implementation of RCM II and Age Replacement-based preventive
maintenance strategies on these five components successfully reduced downtime
and improved machine reliability, with a decrease in downtime from 66.02 hours to
37.87 hours (a 42.64% reduction). This reduction indicates that the scheduled
replacement strategy is capable of addressing failures in critical components,
thereby preventing sudden disruptions that impact the continuity of the production
process.
Keywords: Preventive maintenance, Reliability Centered Maintenance II, Age
replacement, FMEA, schedule discard task
xv

Item Type: Tugas Akhir (Skripsi)
Uncontrolled Keywords: Preventive maintenance, Reliability Centered Maintenance II, Age replacement, FMEA, schedule discard task
Subjek: H Social Sciences > HD Industries. Land use. Labor
Divisions: Fakultas Teknik Industri > (S1) Teknik Industri
Depositing User: Eko Yuli
Date Deposited: 15 Sep 2025 06:24
Last Modified: 15 Sep 2025 07:48
URI: http://eprints.upnyk.ac.id/id/eprint/43683

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