Analisis Estimasi Keandalan (Reliability) dan Mean Time to Failure (MTTF) pada Komponen Seal Silinder Hidrolik Mesin Hot Press
Reliability Estimation Analysis and Mean Time to Failure (MTTF) of Hydraulic Cylinder Seal Components in Hot Press Machines
DOI:
https://doi.org/10.56338/jks.v9i9.11942Keywords:
Seal Hidrolik, Analisis Keandalan Distribusi Weibull, Mean Time to Failure (MTTF), Pemeliharaan Preventif., Hydraulic Seal, Reliability Analysis,, Weibull Distribution, Mean Time to Failure (MTTF), Preventive Maintenance.Abstract
Penelitian ini bertujuan untuk mengidentifikasi karakteristik distribusi data kegagalan pada komponen seal hidrolik, menganalisis tingkat keandalan (reliability) komponen untuk mengetahui probabilitas komponen dapat berfungsi dengan baik dalam interval waktu tertentu, serta menentukan nilai Mean Time to Failure (MTTF) sebagai dasar dalam memberikan rekomendasi jadwal penggantian komponen secara proaktif bagi departemen maintenance PT XYZ. Penelitian ini menggunakan metode mixed methods dengan pendekatan studi kasus pada komponen seal silinder hidrolik mesin hotpress di Departemen Pad and Shoe PT XYZ. Analisis kualitatif menggunakan metode 5 Why untuk mengidentifikasi akar penyebab kegagalan, sedangkan analisis kuantitatif menggunakan reliability engineering dengan distribusi Weibull untuk menganalisis keandalan dan menentukan nilai Mean Time to Failure (MTTF). Data diperoleh melalui observasi, wawancara, studi dokumentasi, dan studi pustaka, dengan menggunakan data historis kegagalan komponen seal periode Februari–April. Hasil analisis digunakan sebagai dasar penyusunan rekomendasi Corrective Action and Preventive Action (CAPA) yang mengacu pada ISO 9001:2015 Klausul 10.2. Hasil penelitian menunjukkan bahwa pola distribusi kegagalan bersifat deterministik-progresif (wear-out) dengan laju kegagalan λ = 0,00625 kegagalan/jam, serta parameter Weibull β = 1,21 dan η = 170 jam. Nilai keandalan komponen menurun seiring waktu operasi, yaitu 79,66% pada jam ke-50, 59,09% pada jam ke-100, dan 39,48% pada MTTF 160 jam. Nilai MTTF sebesar 160 jam menjadi acuan rekomendasi penggantian preventif pada 128 jam atau interval 37–59 jam untuk mencapai target keandalan R(t) ≥ 70–80%. Analisis 5 Why menunjukkan bahwa akar penyebab utama kegagalan adalah ketidaksesuaian spesifikasi material seal NBR dengan kondisi operasi mesin 150°C, yang diperparah oleh belum adanya sistem perawatan preventif berbasis data keandalan. Penyebab kegagalan meliputi degradasi termal material NBR (35,7%), pressure spike (25,0%), kontaminasi fluida hidrolik (17,9%), mis pemasangan seal (14,3%), dan pengoperasian melampaui interval penggantian optimal (7,1%).
This study aims to identify the failure data distribution characteristics of hydraulic seal components, evaluate component reliability by determining the probability of the components operating properly within a specified time interval, and determine the Mean Time to Failure (MTTF) as a basis for developing proactive component replacement schedules for the maintenance department of PT XYZ. The study employed a mixed-methods approach with a case study focusing on the hydraulic cylinder seals of a hot press machine in the Pad and Shoe Department of PT XYZ. Qualitative analysis was conducted using the 5 Why method to identify the root causes of failure, while quantitative analysis applied reliability engineering and Weibull distribution to evaluate component reliability and determine the Mean Time to Failure (MTTF). Data were collected through observation, interviews, document analysis, and literature review, using historical failure data of seal components from February to April. The analytical results were used as the basis for developing Corrective Action and Preventive Action (CAPA) recommendations in accordance with Clause 10.2 of ISO 9001:2015. The results showed that the failure distribution pattern was deterministic-progressive (wear-out), with a failure rate of λ = 0.00625 failures/hour and Weibull parameters of β = 1.21 and η = 170 hours. Component reliability decreased with operating time, reaching 79.66% at 50 operating hours, 59.09% at 100 hours, and 39.48% at the MTTF of 160 hours. The MTTF value of 160 hours was used as the basis for recommending preventive replacement at 128 hours or within an interval of 37–59 hours to achieve a reliability target of R(t) ≥ 70–80%. The 5 Why analysis identified the primary root cause of failure as the incompatibility between the NBR seal material specifications and the machine operating temperature of 150°C, further exacerbated by the absence of a reliability data-based preventive maintenance system. The identified failure causes included thermal degradation of NBR material (35.7%), pressure spikes (25.0%), hydraulic fluid contamination (17.9%), improper seal installation (14.3%), and operation beyond the optimal replacement interval (7.1%).
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