ANALISIS RISIKO KEGAGALAN MESIN GENSET KOMATSU EGS380 MENGGUNAKAN PENDEKATAN RELIABILITY CENTERED MAINTENANCE (RCM) DAN FAILURE MODE AND EFFECT ANALYSIS (FMEA) PADA PT XYZ

Abstract

The reliability of generator sets plays an important role in maintaining the continuity of industrial operations, particularly as a backup power source during disruptions to the main electrical supply. Failures in generator components can increase machine downtime, interrupt production processes, and raise maintenance costs. This study aims to identify critical components, determine the priority level of failure risks using the Failure Mode and Effect Analysis (FMEA) method, and establish appropriate maintenance strategies through the Reliability Centered Maintenance (RCM) method. This research employed a quantitative descriptive approach using historical failure data of the Komatsu EGS380 generator set collected from January to December 2025 through observations, interviews, documentation, and literature review. FMEA was applied by evaluating the Severity (S), Occurrence (O), and Detection (D) of each failure mode, followed by the calculation of the Risk Priority Number (RPN) to determine maintenance priorities. Components with the highest RPN values were subsequently analyzed using Logic Tree Analysis (LTA) within the RCM framework to identify the most appropriate maintenance strategies. The results indicate that FMEA effectively identifies critical components with the highest failure risks, enabling maintenance activities to be prioritized more systematically. Furthermore, the RCM analysis provides appropriate maintenance recommendations based on the characteristics and consequences of each failure mode, resulting in more effective and planned maintenance activities. The integration of FMEA and RCM is expected to improve generator reliability, reduce downtime, minimize maintenance costs, and support the continuity of industrial operations.