Planning preventive maintenance for press machine using Reliability Centered Maintenance (RCM) method: a case study in a plantation company

This research focuses on the organized preventive maintenance scheduling of screw press machine for palm oil processing machine in maintaining the company’s productivity and product quality. The minimization of failure risk and productivity enhancement was investigated by means of Reliability Centered Maintenance (RCM) methodology. The preventive maintenance plan was developed based on Failure Modes and Effects Analysis (FMEA) for critical components such as worm screws, bearings, lengthening shafts, and press cages in determining risk and crucial factor which affects productivity. Reliability data from January to December 2023 indicated the initial conditions of these components. Data for this study were collected over a 12-month period, from January to December 2023, to characterize the baseline operational conditions of the system components. Through the application of the proposed reliability-centered maintenance approach, it was determined that achieving a target reliability level of 70% requires a structured maintenance schedule. This includes reconditioning the worm screws every 22 days using SS 304 electrode wire, replacing bearings at 22-day intervals prior to reaching their estimated technical lifespan, inspecting bolts and nuts on the lengthening shaft every 17 days, and inspecting and cleaning the press cage every 18 days. Failure Modes and Effects Analysis (FMEA) confirmed that the implementation of this maintenance strategy significantly reduces the risk of screw press machine failures, mitigates unplanned production downtime, and enhances overall operational efficiency. These improvements contribute to meeting production targets effectively in the context of a competitive global manufacturing environment.