Analisis keandalan mesin jet dyeing menggunakan metode RCM dan FMEA pada industri tekstil
DOI:
https://doi.org/10.33019/jzhe0044Keywords:
jet dyeing, downtime, RCM, FMEA, preventive maintenanceAbstract
The high frequency of downtime on Tonghue jet dyeing machines at PT. Toyobo Manufacturing Indonesia significantly reduces production efficiency and system reliability. This study aims to identify failure modes, analyze downtime levels, and establish appropriate maintenance strategies based on historical data from January 2020 to December 2024. The methodology employs Reliability Centered Maintenance (RCM) supported by MTBF, MTTR, and Failure Mode and Effects Analysis (FMEA). Results indicate that failures are dominated by leakage (75 of 144 total incidents) and component wear, particularly in mechanical seals, bearings, and packing. Machine T 30-2 recorded the highest failure frequency (31 incidents, MTBF = 45,106 minutes), while machine T 20-2 exhibited the longest downtime (13,160 minutes, MTTR = 506 minutes/incident). FMEA analysis yielded the highest Risk Priority Number (RPN) of 192 for machines T 20-2 and T 30-2. Total potential production loss across all machines was estimated at 15,524.3 kg. Based on MTBF values, preventive maintenance intervals are proposed at 80% of the MTBF, ranging from 25.1 to 40.9 operational days per machine, which is projected to substantially reduce production losses if consistently implemented.
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