Cost-Integrated Lean Maintenance to Reduce Maintenance Cost
Main Article Content
Keywords
Maintenance, Lean Maintenance, Waste, Process and Time Driven Activity Based Costing, PUGH
Abstract
The company has always prioritized cost reduction. In this study, the researchers aimed to decrease maintenance costs by actively eliminating expensive non-value-added processes. The study employed Process and Time Driven Activity Based Costing to integrate cost with the activities performed. By conducting maintenance value stream mapping, the researchers identified various forms of waste, such as centralized maintenance, ineffective data management, poor inventory management, inadequate maintenance, under-utilization of resources, and waiting time for maintenance resources. Several alternative improvement options were proposed, and the Pugh method was used to compare and select the most promising alternatives or combinations of alternatives. The third alternative, which involves conducting internal training and implementing standard operating procedures for maintenance technicians, supervisors, and machine operators, as well as integrating an IT system for maintenance and creating an equipment and spare parts inventory database, was chosen as the highest-ranking option. The results showed that this approach reduced processing time for administrative activities, lowered corrective maintenance costs, and improved maintenance efficiency for both preventive and corrective maintenance.
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References
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Putu Dana Karningsih, Institut Teknologi Sepuluh Nopember
Putu Dana Karningsih is an Assistant Professor, and Head of Manufacturing Systems Laboratory of Industrial and Systems Engineering Department at Institut Teknologi Sepuluh Nopember (ITS) Surabaya, Indonesia. She earned B.Eng. in Mechanical Engineering from the University of Indonesia (UI), Jakarta, Indonesia, Masters in Engineering Science and Ph.D. in Manufacturing Engineering and Management from University of New South Wales, Sydney (UNSW), Australia. Her research interests include manufacturing systems, lean systems, design for X, concurrent engineering, and supply chain risk management. Currently, she supervises postgraduate students with topics: design for modularity; lean warehouse; design for manufacturing and assembly; lean services, frugal innovation, and smart product development.
Winda Puspitasari, Institut Teknologi Sepuluh Nopember
Winda Puspitasari received her Bachelor's degree from Safety and Health Engineering Department, Politeknik Perkapalan Negeri Surabaya (PPNS) and earned her Master degree from the Industrial and Systems Engineering Department, Institut Teknologi Sepuluh Nopember (ITS), Surabaya, Indonesia. Her job experience was almost three years in the areas of quality, health, and environment department. Her research interests are quality, productivity, and industrial management.
Moses Laksono Singgih, Institut Teknologi Sepuluh Nopember
Moses Laksono Singgih is a Professor at the Department of Industrial and Systems Engineering, Institut Teknologi Sepuluh Nopember (ITS), Surabaya, Indonesia. He received his Bachelor's and Master's degree from Industrial Engineering Department, Institut Teknologi Bandung (ITB), Indonesia. He received Ph.D. from the University of Queensland, Australia. His research interests are productivity, quality, and smart manufacturing systems. Currently, he supervises postgraduate students with topics: a design for manufacturing and assembly (DFMA); quality management; lean six sigma; internet of things; sharing economy; circular economy and product-service systems. His publications can be found at https://www.researchgate.net/profile/Moses-Singgih
