M A IN T E N A N

M A IN T E N A N C E H IS T O R Y Predictive Maint. • Condition based maint. • Deteksi gejala kerusakan • Prediksi kapan akan rusak • Jadwalkan perbaikan sbl rusak 3 rd Generation Preventive Maint. • Maint. Periodic terjadwal • Replace/rebuild secara periodic sesuai standar umur 2 nd Generation Corrective/Unplanned Maint. • Tidak ada program maint • Operasikan sampai rusak, baru lakukan perbaikan Dimanakah kita sekarang ? apa misi jangka panjang kita ? 1 st Generation apakah kita mendapat vendor support ?

M A IN T E N A N C E H IS T O R Y Predictive Maint. • Condition based maint. • Deteksi gejala kerusakan • Prediksi kapan akan rusak • Jadwalkan perbaikan sbl rusak 3 rd Generation Preventive Maint. • Maint. Periodic terjadwal • Replace/rebuild secara periodic sesuai standar umur 2 nd Generation Corrective/Unplanned Maint. • Tidak ada program maint • Operasikan sampai rusak, baru lakukan perbaikan Dimanakah kita sekarang ? apa misi jangka panjang kita ? 1 st Generation apakah kita mendapat vendor support ?

CORRECTIVE MAINTENANCE • Siklus Operate Failed Repair REACTIVE MAINTENANCE · Tak ada waktu utk menganalisa kerusakan · Perbaiki hanya jika rusak · Tak ada data untuk dipelajari · Semua aktivitas adalah UNSCHEDULED ! VERY HIGH MAINTENANCE COST · Lembur · Loss production · Inventory tinggi · Resiko tinggi SHORT COMPONENT LIFE Anda tidak perlu melakukan apapun sampai terjadi kerusakan, kemudian perbaiki !

PREVENTIVE MAINTENANCE • Siklus Operate Periodic maintenance LOW RISK • Kepastian aktivitas maint. Tinggi • Unscheduled breakdown turun Ganti komponen mesin Anda secara periodic sesuai standar umurnya, tidak peduli komponen itu masih bisa diperpanjang umurnya atau tidak ! Run Periodic Maint. Schedule ! SHORT COMPONENT LIFE • Tak ada upaya perpanjangan umur komponen · Tak ada analisa akar masalah MAINT. • Waktu dan biaya kurang efisien • Production loss dari unscheduled downtime masih ada SCHEDULE MODERATELY HIGH MAINT. COST

PREDICTIVE MAINTENANCE • Siklus Condition Monitoring Operate Monitor terus kondisi mesin Anda setiap waktu, jika muncul gejala kerusakan, perbaiki sebelum jatuh rusak ! Perpanjang umur komponen mesin Anda jika Trend Performance-nya masih baik ! Operate Scheduled repair Trend Analyses Wow …. ini biangnya ! INCREASED COMPONENT LIFE EXPECTATION · Minor problem diperbaiki lebih dini · Data history memperkuat pembelian equipment · Down time selalu terjaga minimum

Maintenance Processes Maintenance Vision PAMA MAINTENANCE CONCEPT High Availability with Reliable Cost Preventing failure Correcting failure Predicting failure Good Cleaning of Machines Good Maintenance Management

PAMA MAINTENANCE PROCESSES Cleaning of Machines P 2 H - Pre use check Maintenance Management Maintenance Processes Periodical Service Programs : PPM, PPU, PAP, PPB Component Overhaul Midlife ht ! ig Do it r

CLEANING OF MACHINES Kebersihan mesin adalah dasar bagi repair & maintenance quality. Þ Menghindari kerusakan akibat kotoran, lumpur, debu, dan kontaminasi bahan mudah terbakar. Þ Meningkatkan ketajaman inspeksi Þ Meningkatkan kenyamanan kerja maintenance Þ Meningkatkan kenyamanan operasi Bersihkan equipment Anda sebelum scheduled maintenance ! Buatlah jadwal pencucian untuk equipment Anda !

P 2 H = PROGRAM PEMERIKSAAN HARIAN Pre Use Check oleh Operator • Gunakan segala sumber untuk memperoleh informasi kondisi equipment Anda ! Menjamin bahwa mesin benar siap operasi • Mengetahui ketidaknormalan mesin lebih dini • Mengetahui user’s opinion tentang kondisi mesin Cek panel cabin Libatkan pengguna equipment Anda dalam maintenance business ! Cek Inspect kondisi umum Cek udara bertekanan Cek battery Cek kebocoran Cek ban / undercarriage Cek brake

PERIODICAL SERVICE • Maintenance rutin dengan dasar interval 250 , 500 , 1000 , 2000 , 6000 operating hours • Mencegah breakdown unscheduled akibat penurunan normal performance oil dan parts • Mendeteksi kerusakan lebih dini Scheduled backlog repair Change oil Greasing Change filter Change corrossion resistor General check & adjustment Change water coolant Change air cleaner

MIDLIFE • Rebuild/replacement rutin atas komponen kecil / asesoris dengan dasar setengah standar umur komponen besar (6000 – 7000 operating hrs ) • Mencegah breakdown unscheduled akibat penurunan normal performance komponen kecil. Midlife Alternator Midlife Starting Motor Midlife Compressor Midlife Turbocharger Midlife nozzle Midlife Waterpump

12 COMPONENT OVERHAUL • Rebuild/replacement komponen besar secara rutin berdasarkan life time komponen. – Engine 14000 hrs – Transmission 12000 hrs – Differential 14000 hrs, dst • Mencegah unscheduled breakdown akibat penurunan normal performance komponen besar. Ovh Engine Ovh Transmission/PTO Ovh Pumps Ovh Hydraulic cylinder Ovh undercarriage Ovh Electric Wire Ovh Final Drive

PPM = PROGRAM PEMERIKSAAN MESIN • Machine Condition Monitoring • Inspeksi, pengukuran, dan adjustment mesin secara rutin berdasarkan interval 1000 operating hours • Memprediksi gejala kerusakan, memprediksi umur tersisa, menyusun jadwal perbaikan. Test & adjust engine performance Test & adjust hydraulic performance Inspect noise Test & adjust pump performance Inspect visually, detect crack Inspect thermally Test & adjust electric performance Test & adjust transmission/ PTO performance • Compile data pengukuran • Analisa trend problem dan performance • Prediksi lifetime • Schedule-kan perbaikan

PPU = PROGRAM PEMERIKSAAN UNDERCARRIAGE • Undercarriage Condition Monitoring • Inspeksi, pengukuran, dan adjustment komponen undercarriage secara rutin berdasarkan interval 500 opr hrs (high travel crawler) atau 2000 opr hrs (low travel crawler) • Memprediksi gejala kerusakan, memprediksi umur tersisa, menyusun jadwal perbaikan. Adjust track tension Ukur keausan teeht sprocket Ukur keausan rollers Check modus keausan Ukur keausan link Ukur keausan pin & bushing link Ukur keausan shoe grouser Cek comp. free movement • Compile data pengukuran • Analisa trend keausan • Prediksi lifetime • Schedule kan perbaikan

PAP = PROGRAM ANALISA PELUMAS • • • Oil Lub Condition Monitoring Wear metal analyses Contamination analyses (metal, water, fuel, dirt) Additive deterioration analyses Viscosity Fuel soot GEAR OIL Oil lub condition analyses secara rutin berdasarkan interval : 250 opr hrs (engine oil) 1000 opr hrs (hydraulic oil, gear oil) ENGINE OIL Memprediksi gejala kerusakan, memprediksi umur tersisa, menyusun jadwal perbaikan.

WEAR METAL VISCOSITAS Iron : Sumber keausan : Piston, ring, cylinder, gear, block, head, cam, roller bearing, race. Apa yg menyebabkan Viscosity berubah ? Chrome : Various plating, liner, ring, some shaft gears. Molybdenum : Ring plating, alloy ( juga oil additive, off shelf supplement ) Aluminum : Piston, bushing, thrust, block, blower, cooler cores Viscosity naik : Oil teroksidasi Foaming/Pump Cavitation Emulsi dengan air Jelaga atau kontaminasi padat Viscosity turun : Fuel or kontaminasi terlarut Refrigerant Salah pengisian atau penambahan oil

MAINTENANCE MANAGEMENT • • Maintenance Organization & Information Setup Maintenance Planning & Improvement Setup Machine’s hourmeter Data Calculate & Process it ! MIMS • Average Working Hour • Maintenance Support Setup (Part, Komponen, Tool, Facility) – Inventory – Vendor/Consignment Support – Tools & Facility investment • Maintenance Schedule • Parts process • Manhour calculation

Rebuild 1 st Life hours SCRAP ! Rebuild 2 n d Life hours 3 rd, …dst Cost Availability Optimum Point Reliable COST Cost Availability Optimum AVAILABILITY Setup target maintenance yang balance antara Availability required dengan Cost spent !

MIMS = The Maintenance Information Management Tool Machine operation Input opr. hours MIMS process average working hours MIMS process maintenanc e schedule MIMS process maintenanc e work order MIMS process APL order MIMS process part purchase Maintenance execution MIMS Processing machine history : • Failure history • Repair/Maintenance hystory • Component Tracing Data support for improvement program • R/M duration • R/M manhours • R/M Costing Data support for effective decision • Oil/fuel consumption • Availability, MTBF, etc

IMPROVEMENT PROGRAM • Pit Stop Servicing Fuel service, Greasing & oil service, Routine check service at pit stop station Purpose : Reduce idle time • Backlog Management Potential failure execution during periodic service time Purpose : Reduce unscheduled breakdown • Oil life and component life extend Supported with oil filtering improvement, PAP& PPM condition monitoring Purpose : Reduce material cost, man hour, and downtime • Modification Larger coal bucket, coal vessel, fuel tank Auto lube , etc. HYD OIL ENGINE OIL