Developing Autonomous Maintenance through FMEA-RCM Models to Reduce % Machine Breakdown in Food and Beverages Industry

Abstract

In order to reduce % of breakdown (9 to 16% in semester 1 of 2018) in filling machine type A, Nutrifood Cibitung factory implemented Autonomous Maintenance (AM). Which, operator involves in the maintenance process of the production machine. AM also supports and emphasizes in the proactive-preventive maintenance in the Engineering department. In this research, autonomous maintenance task was developed using Failure Mode Effect Analysis (FMEA) and Reliability Centered Maintenance (RCM) on each part of the machine to determine every failure possibility and the root causes. Autonomous maintenance is developed through an understanding of existing problems or a history of machine breakdown and minimizing the source of deteroriation (Sara, 2015). FMEA-RCM is used to determine every failure possibility and the root causes of the failure. This failure possibility was prevented through the certain task (when, where & how) that is conducted in autonomous maintenance by operator. Scope of the task is limited to 4 tasks: Cleaning, Lubrication, Inspection, and Tightening (CILT) in filling machine type A of Nutrifood Cibitung Factory. Implementation of autonomous maintenance that was developed through FMEA-RCM framework has reduced 40-60% breakdown level from semester 1 of 2018 in filling machine type A. This maintenance activity provides initial detection of a failure in the machine which triggers the maintenance team to fix the problem before getting worse. Autonomous Maintenance also standardizes and increases operator skills in doing maintenance of their machine.