| Citra Jaya Gemilang LLC. is a manufacturing company that make a plastic based product like handle, cd case, etc. The company are obliged to produce with a certain level of quality standard. The problem that are faced by the company is there are still some defects on the product and having a big downtime especially on injection molding machine I-15 KT 180. A maintenance schedule is needed in order to overcome the problems that are occurred in Citra Jaya Gemilang LLC. The first step to know the what the problem is by identifying the critical machine, and then calculating the OEE score, from the OEE results it is known that the average OEE score is 70.2% and it is still below the ideal standard which is bigger than 85%. Next the critical component will be determined based on FMECA and critical analysis, by knowing the critical component a compatible distribution will be searched and used for changing schedule. Deciding the component changing interval will be done by using 4 types of damage distribution such as Weibull distribution, exponential distribution, normal distribution and lognormal distribution. The proposed critical component maintenance system are the Age Replacement and Block replacement model. This maintenance system will increase availability and reliability rate. Determining the maintenance schedule was based by 3 specific criteria which is availability, reliability and maintenance cost. The results found are, by changing component using the age replacement model the interval for the components are; for heater component/ element is 34 days, for O-ring component 42 days, for bearing component 33 days, seal component 39 days, screw component 31 days, hydraulic hose component 41 days, machine button component 49 days, contactor component 67 days. Clamping nodes component 71 days, heat exchanger component 108 days, indicator lamp component 59 days, motor pump component 121 days. |