PERANCANGAN SISTEM PREVENTIVE MAINTENANCE BERDASARKAN ANALISIS RELIABILITY CENTERED MAINTENANCE (RCM) DAN MODEL AGE REPLACEMENT DALAM MENJAGA KEANDALAN MESIN (STUDI KASUS: PT. XYZ)

Fahmi Muharomi Dzikri, NIM.: 22106060024 (2026) PERANCANGAN SISTEM PREVENTIVE MAINTENANCE BERDASARKAN ANALISIS RELIABILITY CENTERED MAINTENANCE (RCM) DAN MODEL AGE REPLACEMENT DALAM MENJAGA KEANDALAN MESIN (STUDI KASUS: PT. XYZ). Skripsi thesis, UIN SUNAN KALIJAGA YOGYAKARTA.

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Abstract

The cement industry is a sector that heavily relies on the reliability of production machinery, particularly the Raw Mill machine, which plays a crucial role in the raw material grinding process. PT XYZ as one of the largest cement manufacturers in Indonesia, faces the challenge of maintaining and improving the effectiveness and efficiency of its production processes. This study aims to measure machine effectiveness using the Overall Equipment Effectiveness (OEE) method, identify critical components and maintenance strategies using Reliability Centered Maintenance (RCM), determine optimal component replacement intervals using the Age Replacement model, and design a maintenance decision support system. The results show that the average OEE value of the Raw Mill machine is 66.5%, which is still below the world-class standard of 85%, with an availability of 79.57%, performance of 78.52%, and quality of 100%. The optimal maintenance strategy based on RCM is a scheduled discard task for the grinding roller and table liner components, as well as a scheduled restoration task for conveyor system components such as the belt conveyor, lagging snub pulley, primary belt cleaner, return roller, and impact roller. The optimal replacement intervals obtained are 5,792 hours or 241 days for the grinding roller and 5,832 hours or 243 days for the table liner, resulting in cost savings of 41.80% and 37.03%, respectively. The design of the Preventive Reliability Management (PRIMA) system is capable of integrating OEE, RCM, and Age Replacement analyses, producing outputs such as OEE values, failure distribution, replacement intervals, and cost analysis. The system has been successfully tested through white-box and black-box testing.

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