Determination of Preventive Replacement Age of V-Belt on the Vibrating Feeder to Minimize Downtime in the Split Stone Plant PT Semen Padang

Arpiani, Murni (2026) Determination of Preventive Replacement Age of V-Belt on the Vibrating Feeder to Minimize Downtime in the Split Stone Plant PT Semen Padang. S1 thesis, Universitas Andalas.

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Abstract

Maintenance planning is essential to ensure machine reliability and production efficiency. The split stone production line at PT Semen Padang consists of machines that operate in an integrated and interconnected system. Under these conditions, failure of a single component can disrupt or even halt the entire production process. One component that significantly contributes to downtime is the V-belt on the Vibrating Feeder machine. Based on historical data, this component recorded a total downtime of 38.25 hours with 20 failure occurrences, including 10 replacement actions during the observation period. This study aims to determine the optimal preventive replacement age of the V-belt on the Vibrating Feeder machine in the split stone production line at PT Semen Padang in order to minimize downtime. The historical data used in this research cover the period from October 2023 to October 2025, including component operating hours and the duration of downtime caused by V-belt failures. The determination of the preventive replacement age was conducted using the Optimal Preventive Replacement Age method, an approach that focuses on identifying the replacement age of a component such that total downtime per unit time is minimized. The analysis results indicate that preventive replacement of the V-belt should be performed after approximately 257 operating hours. Implementing this age is estimated to reduce total downtime by 8% compared to the current reactive maintenance practice. In addition, the system availability reaches 99.35%. From an economic perspective, preventive maintenance does not significantly reduce total operational costs compared to corrective maintenance. This is due to the relatively low downtime under existing conditions and the small difference in maintenance duration. However, preventive maintenance enables better resource planning, thereby reducing cost variability and minimizing unexpected failures that may increase maintenance complexity. These findings indicate that preventive maintenance of the V-belt is technically effective in improving system reliability while also providing benefits in achieving more stable and well-controlled cost management.

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