Analysis of Kernel Heater Machine Maintenance with RCM (Reliability Centered Maintenance) Method

Abstract

The reliability of production machinery is crucial in ensuring efficiency and safety within the palm oil processing industry, where machine failures can disrupt production continuity and increase operational costs. PT. Langkat Sawit Hijau Pratama, which operates Kernel Heater machines for kernel drying, faces challenges in maintaining optimal machine performance due to frequent failures of critical components. This study aims to analyze the maintenance of Kernel Heater machines using the Reliability Centered Maintenance (RCM) method to identify critical components, assess their failure modes, and propose effective maintenance strategies. The methodology integrates Maintenance Significant Item (MSI) identification, Failure Mode and Effects Analysis (FMEA), Logic Tree Analysis (LTA), and reliability calculations to determine Risk Priority Number (RPN), failure rates, and component reliability. The findings reveal that the Steam Pipe has the highest RPN (384) due to leak risks and high steam pressure, followed by Bearings with an RPN of 336. Reliability analysis further shows that the Steam Pipeline has the highest failure rate (0.0026 hours) and the lowest reliability (0.00011 hours), placing it in the safety-critical category, while components such as the Steam Trap and Fan demonstrate higher reliability with minimal downtime. Based on these results, priority maintenance is recommended for the Steam Pipeline and Radiator, whereas routine maintenance is sufficient for the Steam Trap and Fan. The study concludes that applying the RCM method allows systematic identification of critical failures, enhances preventive maintenance planning, reduces downtime, and supports safer and more efficient operations in palm oil processing plants.