Kuliah 2 Maintenance Development and Management IND

7/27/2019 Kuliah 2 Maintenance Development and Management IND

1/20

MAINTENANCE MANAGEMENT


2/20

Types of company based on maintenance point of view

Unaware company:

maintenance as necessary evil, kepentingan kejahatan

an expense to the organization, beban bagi organisasi

a non-value added function, fungsi tambah non-nilai

Competitive company: maintenance as a means for reducing the cost of production,

sebagai sarana untuk mengurangi biaya produksi

use this competitive advantage to lower prices, improve margin profit,

and increase shareholder value, menggunakan keunggulan kompetitif ini

untuk harga yang lebih rendah, meningkatkan marjin laba,

dan meningkatkan nilai pemegang saham

Why this condition happen?


3/20

Competition is something that every company faces, but do companies

truly understand the definition of competition?

competition is the rivalry between two or more businesses striving for

the same costumer or market.,

kompetisi adalah adalah persaingan antara dua atau lebih bisnis berjuang untukcostumer yang sama atau pasar

Companies must constantly improve themselves

in order to avoid being surpassed by competitors,

Perusahaan harus terus memperbaik i dir i

dalam rangka u ntuk mengh indar i dikalahkan o leh pesaing


4/20

But.

The companies today do not have exclusivity in their assets and process

when providing a product or service to the marketplace

they use the same materials and assets to produce their goods

Perusahaan-perusahaan saat ini tidak memiliki eksklusifitas dalam aset

dan proses mereka,ketika memberikan produk atau layanan ke pasar

mereka menggunakan bahan dan aset yang sama untuk memproduksi

barang-barang mereka

How do they differentiate themselves from their competitors?


5/20

Contoh dari organisasi yang bersaing dengan aset yang sangat identik dalam

lingkungan bisnisnya, sebagai contoh NASCAR Racing

Goal: To Finish at 1st place

Fokus seluruh organisasi (tim) melakukan

bagian mereka untuk mendapatkan kapasitas maksimum dari aset


6/20

bagaimana jika pengemudi didikte kru pit kapan dan bagaimana melakukan sesuatu?

bagaimana jika kru pit mengabaikan masukan pengemudi tentang performa mobil?

bagaimana jika para setup engineers tidak mempertimbangkan apa jenis track balapan?

what if.

DECISION


7/20

Worse

lebih buruk

Bestterbaik

Evolveberkembang

Selective learning process

Adopted from Darwinian Model

managers strategically develop their vision for how the companys

products and services will fill the need in the market. They select

the Best Practice to achieve their vision while changing or eliminatingset a inferior practices or policies

Manajer strategis mengembangkan visi mereka untuk bagaimana produk dan

layanan perusahaan akan memenuhi kebutuhan di pasar.

Mereka pilih Best Practice untuk mencapai visi mereka saat mengganti,

menghilangkan, menetapkan praktek atau kebijakan

The managers:

harus menetapkan arah yang jelas, fokus pada visi perusahaan

memerlukan alat navigasi yang baik untuk membantu mereka

mengarahkan organisasi dan memonitor kemajuan


8/20

Production Process continuity is affected by Maintenance System

Proses Produksi kontinuitas dipengaruhi oleh Pemeliharaan Sistem

Process OutputInput

Feed-back


9/20

Main goal of maintenance is reliability

. Production process at optimum speedTujuan utama dari pemeliharaan keandalan

.... Proses produksi pada kecepatan optimal ...


10/20

When a guy goes out on the floor

to fix a machine

Hes not doing maintenance!

Hes doing repair!!!

(Ellis New Product iv i ty Inc.)


11/20

Breakdown Maintenance / kerusakan

Preventive Maintenance / pencegahan Productive Maintenance Total Productive Maintenance Reliability Centered Maintenance

MAINTENANCE DEVELOPMENT


12/20

BREAKDOWN MAINTENANCE

Until after World War II (1950s) Mechanical development was limited Downtime was not a problem;

Breakdown prevention was not a prioritysimple technology and built to last principle occurred Needs for maintenance skill was rarely happen


13/20

PREVENTIVE MAINTENANCE

Until 1960s; changing of human mind-set after World War II Permintaan meningkat sementara pasokan menurun drastis Kebutuhan mekanisasi meningkat

Ketergantungan pada mesin meningkat, juga lebih kompleks Berfokus pada down-time tetapi kegagalan mesin dapat dideteksidan dihindari

Needs for maintenance skill increased Biaya maintenance meningkat dan situasi ini dapat dikelola

dengan perencanaan maintenance dan kontrol, sehingga

kegiatan maintenance bisa lebih efektif dan efisien.


14/20

Selama liburan atau masa perencanaan Shutdown machine ,mesin diperiksa tingkat keausannya. Tindakan yang diperlukanseperti, perubahan tepat waktu bagian usang,perbaikan dll, dilakukan.

operasi pembersihan besar, meminyaki, pemeriksaan dari set up,keselarasan dll, dilakukan.

membantu menciptakan kesadaran dan pengakuan tentang pentingnyakeandalan dan efisiensi ekonomi dalam perancangan pabrik dll


15/20

PRODUCTIVE MAINTENANCE

Until after World War II (1950s) Mechanical development was limited Downtime was not a problem;

Breakdown prevention was not a prioritysimple technology and built to last principle occurred Needs for maintenance skill was rarely happen


16/20

'Productive Maintenance' came into existence. Kesadaran menciptakan sistem cek rutin pada hari ke hari

seperti memeriksa ketatnya mur, baut, kebocoran dll Hal ini menyebabkan'Maintainability Improvement'.

Preventive maintenance and maintainability improvementmembantu kepada'Maintenance Prevention' i.e., mempertimbangkanpengurangan di dalam aktivitas maintenance


17/20

Japan adopted Preventive maintenance and Productivity maintenancein their plants.Seiichi Nakajima in 1971 made Productive Maintenance asTotal Productive Maintenance.

If quality can be responsibilities of the process control people,why not the machine they use also?He created a comprehensive system wherein autonomous maintenancebecame an integral part of productive maintenance system.TPM is achieving PM efficiencies through comprehensive system basedon respect for individuals and total employee participation and

it brought in autonomous maintenance in to the system.

TOTAL PRODUCTIVE MAINTENANCE


18/20

Seiichi Nakajima offered concept of TPM in 1972 (Japan) after studyingby visiting many European and American manufacturers from 60s (1962)

workers productivity increased by 60% accidental breakdown reduced up to 1/100 1/500

Close to zero

Parlor factory

Parlor factory : zashiki part of Japanese home where they entertain

their guests (it keeps immaculately clean)


19/20

Aims at building up a corporate culture that thoroughly pursues productionsystem efficiency improvement (OEE : overall equipment efficiency)

Constructs a system to prevent every kind of loss, for example,to achieve zero accidents, zero defects and zero failures

based on Gemba (actual site) and Genbutsu (actual thing)over the entire life cycle of a production system.

Covers all departments including production, development, marketing,and administration.

Requires all and full involvement from top managementto frontline employees.

Achieves zero losses by overlapping small-group activities.


20/20

TPM can be considered as the medical sciences of machines

Increase production

Employee morale

Job satisfaction

Brings maintenance into focus as necessary and vitally important part

of the business; no longer regarded as a non-profit activity

Documents

Kuliah 2 Maintenance Development and Management IND