DAROJAT, ROFI’UDIN (2026) PENGEMBANGAN PROGRAM EXTENDED LIFETIME MAJOR COMPONENT KOMATSU PC1250-8R BERBASIS CONDITION BASED MAINTENANCE DAN RISK BASED MAINTENANCE. Masters thesis, Institut Teknologi Nasional Malang.
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Abstract
ABSTRAK Peran excavator Komatsu PC1250-8R sebagai alat muat utama pada operasi tambang batubara menuntut tingkat keandalan dan ketersediaan unit yang tinggi, sementara interval general overhaul berkala 18.000 jam menyebabkan biaya pemeliharaan besar dan risiko downtime yang mengganggu kontinuitas produksi. Tekanan efisiensi operasional serta kebutuhan pengendalian biaya mendorong pengembangan program perpanjangan umur pakai komponen utama hingga 25.000 jam dengan tujuan memperoleh strategi pemeliharaan yang lebih adaptif, berbasis kondisi aktual, dan berorientasi risiko. Pendekatan penelitian berbentuk problem solving eksploratif dan eksperimental dengan pemanfaatan data condition based maintenance (CBM) melalui oil analysis dan vehicle health monitoring system (VHMS) sebagai sumber informasi kondisi kesehatan komponen. Data historis kerusakan selanjutnya dianalisis melalui klasifikasi parameter keausan, kontaminasi, dan degradasi pelumas serta identifikasi mode kegagalan. Fault tree analysis (FTA) digunakan untuk menelusuri hubungan sebab–akibat dan mengidentifikasi akar penyebab kegagalan secara sistematis, sehingga faktor kritis yang memicu kerusakan dapat diketahui. Hasil identifikasi tersebut kemudian dievaluasi menggunakan failure mode and effects analysis (FMEA) untuk menilai tingkat risiko melalui perhitungan risk priority number (RPN) guna menentukan prioritas mitigasi dan tindakan pemeliharaan. Integrasi FTA dan FMEA menjadi dasar penerapan risk based maintenance (RBM) dalam penyusunan strategi pemeliharaan yang terarah, efektif, dan berbasis risiko. Hasil analisis menunjukkan parameter kritis pada sistem engine berupa Pb, Cu, Na, dan viskositas, pada sistem hidraulik berupa temperatur oil dan tekanan pompa, serta pada final drive berupa kontaminasi abrasif Si, Fe, Al, dan PQ index sebagai indikator dominan degradasi komponen. Integrasi condition based maintenance dan risk based maintenance (RBM) menghasilkan penurunan potensi breakdown, pengurangan downtime, pengendalian biaya perawatan, dan peningkatan reliability serta physical availability. Kesimpulan penelitian menunjukkan kelayakan pencapaian target extended lifetime 25.000 jam melalui strategi predictive, preventive, dan corrective maintenance berbasis risiko, dengan rekomendasi penerapan monitoring rutin, penjadwalan overhaul adaptif, dan standardisasi program pemeliharaan berkelanjutan. Kata Kunci : CBM, Extended Lifetime, FTA, FMEA, RBM ABSTRACT The role of the Komatsu PC1250-8R excavator as the primary loading equipment in coal mining operations requires high levels of reliability and equipment availability, while the periodic general overhaul interval of 18,000 operating hours results in substantial maintenance costs and downtime risks that disrupt production continuity. Operational efficiency pressures and cost control requirements necessitate the development of a major component lifetime extension program up to 25,000 operating hours to establish a more adaptive, condition-based, and risk-oriented maintenance strategy. An exploratory and experimental problem-solving approach was employed by utilizing condition based maintenance (CBM) data derived from oil analysis and the vehicle health monitoring system (VHMS) as primary sources of component health information. Historical failure records were subsequently analyzed through the classification of wear, contamination, and lubricant degradation parameters to identify potential failure modes. fault tree analysis (FTA) was applied to systematically trace cause–effect relationships and determine the root causes of failures, enabling the identification of critical factors contributing to component degradation. The identified failure mechanisms were then evaluated using failure mode and effects analysis (FMEA) to assess risk levels through risk priority number (RPN) calculations, thereby establishing maintenance priorities and mitigation actions. The integration of FTA and FMEA provides the analytical foundation for implementing Risk Based Maintenance (RBM), ensuring that maintenance strategies are structured, prioritized, and aligned with risk levels to improve reliability, reduce downtime, and optimize maintenance costs.. The results indicate critical parameters in the engine system, including Pb, Cu, Na, and viscosity; in the hydraulic system, including oil temperature and pump pressure; and in the final drive, including abrasive contaminants such as Si, Fe, Al, and the PQ index as dominant indicators of component degradation. The integration of condition based maintenance and risk based maintenance (RBM) reduces breakdown potential, minimizes downtime, controls maintenance costs, and improves reliability and physical availability. The findings confirm the feasibility of achieving the 25,000-hour extended lifetime target through risk-based predictive, preventive, and corrective maintenance strategies, with recommendations for routine condition monitoring, adaptive overhaul scheduling, and standardized sustainable maintenance programs. Keyword : CBM, Extended Lifetime, FTA, FMEA, RBM
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Keyword : CBM, Extended Lifetime, FTA, FMEA, RBM |
| Subjects: | Engineering > Industrial Engineering |
| Divisions: | Program Pasca Sarjana > Teknik Industri S2 > Teknik Industri S2(Tesis) |
| Depositing User: | Rofiúdin Darojat |
| Date Deposited: | 05 Aug 2026 07:06 |
| Last Modified: | 05 Aug 2026 07:06 |
| URI: | http://eprints.itn.ac.id/id/eprint/16332 |
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