Analisis Kegagalan Komponen Kritis Pada Unit Washing Roll Dengan Metode Failure Mode And Effects Analysis (Fmea) Di Wood Preparation Pt Indah Kiat Pulp & Paper

The washing roll machine at PT Indah Kiat Pulp & Paper (IKPP) Perawang is highly susceptible to mechanical failures due to heavy dynamic loads, causing up to 28.5 hours of production downtime in six months. This study aims to identify and mitigate critical component failures using the Failure Mode and Effects Analysis (FMEA) method. Out of 32 identified failure modes, the Pareto Diagram (80/20 rule) prioritized 4 most critical components based on the highest Risk Priority Number (RPN): loose bearing housing bolts (601.35), worn transmission Chain pins (488.44), bent main Shaft (425.85), and broken/detached Chain connecting links (375.11). The 5 Whys analysis revealed that these failures are triggered by continuous shock loads and the lack of standardized routine maintenance. As a solution, a Preventive Maintenance Schedule based on international critical limits (ISO 10816-3 for vibration, SKF guidelines for bearing temperature, and ANSI standards for Chain slack) is proposed. This recommendation is expected to transform the maintenance system from corrective to predictive, thereby improving overall machine reliability.