ANALYSIS AND SIMULATION OF RELIABILITY IMPROVEMENT IN GEAR PUMP MACHINE USING LIFE CYCLE COST METHOD IN XYZ COMPANY
Abstract. Gear pump machine 51-98P01 is a machine that is available at XYZ company, which functions as a transportation machine for raw materials from one production process. Because of its function, if there is a downtime occurs on the machine, production process will stop operating because the raw material cannot be flowed. Those problems caused a large amount of expenses that company should pay because late of production. Downtime occurs due to several factors, such as failure to components on the machine, age that has exceeded the optimal age limit, and the number of maintenance crew that is not optimal. To solve the problems, the Life Cycle Cost (LCC) method is used to determine the optimum age of the machine and the optimal number of maintenance crew using the Life Cycle Cost (LCC) method. In addition, a calculation of the proposed maintenance time interval is also carried out to achieve a certain reliability value using a simulation of reliability improvement to see the effect of reliability on the total LCC. Based on data processing using the LCC method, it is known that LCC in 2018 is Rp1,333,195,316 while the optimum LCC is Rp.690,180,267 with optimal machine life of six years and the number of crew maintenance is one person. Simulation of reliability improvement that carried out on the gear pump machine components shows a decrease of total LCC of the machine.
Keywords: Downtime, Failure Cost Life Cycle Cost, Maintenance Crew, Reliability
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