GEARLESS MILL DRIVE MAINTENANCE PLANNING RISK ANALYSIS USING FAILURE MODE AND EFFECT ANALYSIS AND ANALYTIC HIERARCHY PROCESS

• Main Author: Fibrianto, Amora
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/81924
• Institution: Institut Teknologi Bandung

The Gearless Mill Drive (GMD) is a critical production equipment in copper concentrator mill processing plants, playing an integral role in the overall production process. The GMD utilizes a synchronous motor, with the rotor coil forming an integral part of the mill's construction. The rising demand for copper due to electrification programs has prompted stakeholders to demand high availability and utilization for this production unit. However, optimizing the GMD maintenance system presents complex challenges and requires thorough preparation. This is because processing plants and mines located in remote areas face significant geographical and operational challenges. Maintenance efforts have been implemented to extend the machine's intended operating life. However, the effectiveness of these maintenance activities needs to be re-evaluated. Risk-cost analysis can be utilized to assess the effectiveness of maintenance work in mitigating machine failure risks and balancing cost components, including maintenance costs and opportunity costs arising from maintenance activities. Failure Mode and Effect Analysis (FMEA), a Six Sigma tool, can be employed to evaluate potential risks and their impact on machinery or production units, as well as the effectiveness of damage detection and prevention systems, including maintenance programs. FMEA does have certain limitations, one of which is the subjectivity of the assessment by the source. To address the challenges and limitations of FMEA, the Analytic Hierarchy Process (AHP), a Multi Criteria Decision Making (MCDM) tool, can be utilized. In this study, AHP is employed for Risk-Cost analysis, where: 1) Risk factors of each failure mode are compared pairwisely; 2) Risk factors are compared with cost factors to determine the criteria that prioritize decision-making in an aggregate manner; 3) Maintenance solution alternatives with a work scheduling framework are used as alternatives in AHP. Five maintenance work scheduling alternatives have been identified in the formulation process. The decision-makers perceived the need to critically review maintenance work scheduling and understand the importance of maintenance activities. As a result, the implementation of a run-to-failure strategy was considered the least desirable alternative. Risk-cost analysis in the maintenance domain facilitates the optimization of maintenance activities with a correspondingly quantifiable risk level. This optimization can maximize the availability and utilization of production units to achieve production targets. It is crucial for all stakeholders to ensure that production units can operate productively and safely beyond their intended operating lifetime.