Maintenance Analysis of Raw Mill Machines in Cement Production

Abstract

PT X is one of the companies that produces cement in Indonesia. Engine breakdowns do happen occasionally in raw mill machines in PT X. This study analyzed the cause of occasional breakdowns. The CC-2 raw mill machine had an average operational time of 4.8 days per week and a total breakdown time of 137.76 h. Overall equipment effectiveness (OEE) analysis revealed an average OEE of 57%, with the performance rate being the most significant influence. The OEE of the CC-2 raw mill machine is below 65%, which is unacceptable, because it causes significant economic losses and very low company competitiveness. Failure mode and effects analysis (FMEA) identified various causes for breakdowns, such as gas supply failure, wear/fatigue, electrical issues, and raw material quality. Suggestions for solutions are provided, including repairs, replacements, and preventive maintenance.

Keywords

• total productive maintenance
• overall equipment effectiveness
• failure mode and effects analysis