EVALUASI STRATEGI OPERASI MAINTENANCE DAN MANAGEMENT CONTROL SYSTEM PADA PERUSAHAAN XYZ DENGAN PENDEKATAN RELIABILITY CENTERED MAINTENANCE

Rokhmatulloh, Dr. Eko Suwardi, M.Sc., CMA.

2013 | Tesis | S2 Magister Manajemen

Organisasi bisnis umumnya kurang menyadari pentingnya kontribusi efektifitas strategi maintenance pada kinerja bisnis. Sebagain masih melihat maintenance sebagai bagian dari pusat pengeluaran biaya. Untuk melihat peran maintenance terhadap kinerja bisnis, metrik kinerja utama maintenance plant availability perlu dianalisa dan dibandingkan dengan product process matrix. Beberapa process mungkin tidak membutuhkan level kinerja availability yang tinggi, tetapi bagi prosess Continuous, kinerja plant availability (merefleksikan kinerja capacity utilization) adalah segalanya dan berkontribusi langsung pada kinerja bisnis. Perusahaan XYZ (berikutnya disebut PERUSAHAAN) sebagai objek tinjauan utama tesis ini dan industrinya berada pada product process matrix Continuous. Perusahaan harus mengkompensasikan biaya modal tinggi dan investasi padat modal fixed asset dari fasilitas produksi dengan kinerja capacity utilization dan volume produksi yang setinggi-tingginya dengan biaya maintenance yang optimal. Kinerja maintenance juga berkontribusi pada kinerja quality dan speed, 2 element lain dari Overall Equipment Effectiveness yang menjadi kinerja primer operasi perusahaan. Tesis ini mengevaluasi keselarasan strategi dari level korporasi ke level unit bisnis (PERUSAHAAN), dari level unit bisnis ke level divisi operasi, dan berikutnya dengan lebih komprehensiv, dari level divisi operasi ke level department maintenance. Reliability Centered Maintenance dipakai sebagai checklist riset dalam mengevaluasi kefektifan strategi maintenance. Evaluasi juga mencakup Management Control System maintenance. Hasilnya akan menyimpulkan kemungkinan potensi gap, potensi opporunities dan benefit, dan rekomendasi untuk perbaikan strategi dan mangement system sebagi upaya mewujudkan potensi opportunity dan benefit.

Many business organizations sometime do not realize importance of high contribution of maintenance strategies effectiveness to business performance. Some organization think maintenance is always seen as expense center. To see maintenance roles objectively to the business performance, the main/key maintenance performance metric of production/service availability must be analyzed and compared to product process matrix. Some process might not highly require level of availability but for those with process Continuous, availability (reflects to capacity utilization) performance is everything to the business performance. Company XYZ (hereinafter refers to “Company”) as the observed object and the comodity product industry are in this product process matrix Continuous. Organization shall compensate very high and compact investment for fixed assets of production facilities with huge production volume meaning that production availability shall be achieved as high as possible with optimized maintenance cost. Maintenance function also contributes to product quality and production speed, another elements of Overall Equipment Effectiveness which is the primary performance of Company operation performance. This thesis evaluates alignment of strategies briefly from corporate level to business unit (this Company) level, from business unit level to division (in this case, operation strategies) level, and further broadly from division operation level to department level (in this case, maintenance). Reliability Centered Maintenance (hereinafter referred to RCM) is approached as research checklist in evaluating Company maintenance strategies effectiveness. The evaluation on maintenance strategies is extended to Management Control System of maintenance. The result would conclude any possibilities of gaps, potential oppotunities & benefit, and recommendations for improvement on strategies and management system.

Kata Kunci : Capacity Utilization, Maintenance Strategy, Management Control System, Operation Strategy, Overall Equipment Effectiveness, Plan Availability, Product Process Matrix, Reliability Centered Maintenance