PT. Kurabo Manunggal Textile Industries (PT. KUMATEX) is a company which specialized in manufacturing strings for textile industries needs. The problem they are facing now is that they can not fulfill customer’s demands as well as deliver the orders on the determined time because of the series of machines breakdown. Inadequate maintenance may cause this problem so that a scheduled one is needed as a prevention. Based from the description above, this research will analyze three aspects: cause of failure, changing time for components, and its effects on availability and reliability. A group of critical machines are chosen from the highest downtime value of each
machines and group of critical sub-machines are chosen from the highest occurance of breakdown frequencies. Effectiveness rate of the machines is calculated by using OEE, then an analysis called FMEA is performed to trace the causes of machines breakdown. Afterwards, an analysis for determining linkages among each breakdown is done by using FTA. Breakdown of a bearing becomes the main priority to be handled. The process of schedulling critical components started as follows: searching for the appropriate distribution, then determining the changing and checking time as well as their influence on availability and reliability. Obtained results show that three components (Bearing 1309, Bearing 6206, and Belt Pulley) give a high value of availability. However, it can not improve the reliability significantly. Replacement of Bearing 6004 with Age Replacement gives 2,905% more on reliability than Block Replacement. However from the perspective of total availability, Block Replacement gives 0,09% more than Age Replacement. A maintenance system that is supported by scheduled maintenance and proper Standard Operating Procedures (SOP) could increase the effectiveness of machines as well as minimize the downtime. |