ANALISIS PENENTUAN WAKTU PERAWATAN MESIN KOMPRESOR CO2 GB-101A PADA LINI PRODUKSI PUPUK UREA MENGGUNAKAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) DAN AGE REPLACEMENT (STUDI KASUS : PT. PUPUK KUJANG INDONESIA)

Muhammad Fauzi Akmal, NIM.: 21106060038 (2025) ANALISIS PENENTUAN WAKTU PERAWATAN MESIN KOMPRESOR CO2 GB-101A PADA LINI PRODUKSI PUPUK UREA MENGGUNAKAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) DAN AGE REPLACEMENT (STUDI KASUS : PT. PUPUK KUJANG INDONESIA). Skripsi thesis, UIN SUNAN KALIJAGA YOGYAKARTA.

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Abstract

Machines are a crucial component of production for companies in processing a product. Even minor machine failures can have small to large impacts on the production process and disrupt the stability of operations. PT. Pupuk Kujang is a chemical company that produces chemical fertilizers such as urea and ammonia. In this company, there are machines with high failure rates. There were 38 breakdowns recorded from 2020 to 2024, involving various components, causing the production machines to be down for a total of 476 hours. This study aims to determine the appropriate maintenance actions and maintenance intervals. Based on qualitative data analysis using FMEA, six components were identified as having the highest impact on machine failure, contributing to approximately 80% of the issues. These components are the turbine servo motor, discharge valve, suction valve, regulating valve, gasket deckle and oil seal regulating. These components are the focus of the study. Using LTA and the RCM II decision worksheet, it was found that the suction valve, discharge valve, gasket deckle, and oil seal regulating components should undergo scheduled discard tasks, while the regulating valve and turbine servo motor should be maintained through scheduled on-condition tasks. Based on quantitative data analysis using the age replacement method to determine reliability, it was found that maintenance for the turbine servo motor should be carried out at 4,425 operating hours. The machine downtime percentage significantly decreased after applying the age replacement method. Specifically, the downtime reduction was 30,97%, for the turbine servo motor, 18,73% for the discharge valve, 53,40% for the suction valve, 9,89% for the regulating valve, gasket deckle 61,68%, and 56,29% for the oil seal regulating.

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