A Maintenance Strategy for Dosing Pumps Using Reliability-Centered Maintenance (RCM) and Spare Parts Ordering to Improve the Reliability of the Clean Water Supply System at PT. Dain Celicani Cemerlang

Johannes Kevin  Purba; Aulia  Ishak; Nurhayati Nurhayati

doi:10.70716/reswara.v4i3.534

Authors

Johannes Kevin Purba Magister Teknik Industri Fakultas Teknik, Universitas Sumatera Utara, Medan, Indonesia Author
Aulia Ishak Magister Teknik Industri Fakultas Teknik, Universitas Sumatera Utara, Medan, Indonesia Author
Nurhayati Magister Teknik Industri Fakultas Teknik, Universitas Sumatera Utara, Medan, Indonesia Author

DOI:

https://doi.org/10.70716/reswara.v4i3.534

Keywords:

Reliability Centered Maintenance (RCM), Sparepart Ordering, Dosing Pump

Abstract

The continuity of the clean water distribution process at PT Dain Celicani Cemerlang is highly dependent on the reliability of the dosing pumps. However, the maintenance system currently in place is still reactive (corrective maintenance), resulting in high operational downtime and uncontrolled maintenance costs. This study aims to improve the reliability of the clean water supply system by designing a maintenance strategy based on Reliability-Centered Maintenance (RCM) and optimizing spare parts management through a spare parts ordering system. The research method used is descriptive quantitative analysis, which involves analyzing reliability parameters such as Mean Time Between Failures (MTBF), Mean Time To Repair (MTTR), and Risk Priority Number (RPN) through a Failure Mode and Effect Analysis (FMEA) approach. In addition, the Economic Order Quantity (EOQ) and Period Order Quantity (POQ) methods were used to determine the most efficient spare parts ordering policy. The research results show that the implementation of appropriate RCM strategies (such as preventive maintenance and scheduled replacement) can significantly reduce system downtime by 89.21% and increase machine availability from 96.73% to 99.65%. From a cost perspective, implementing RCM yields savings of 24.27%, while integrating the EOQ and POQ methods into spare parts management reduces inventory costs by up to 41.73% compared to the company’s current system. In conclusion, the integration of RCM with a structured spare parts ordering system is highly effective in ensuring the company’s operational stability and cost efficiency.

References

Ali, A., & Abdelhadi, A. (2022). Condition-based monitoring and maintenance: state of the art review. Applied Sciences , 12 (2), 688.

Amani, YAY, Ritonga, AA, Putra, MIAP, Nur, FM, & Hidayat, H. (2026). Arrow C-106 Engine Performance Analysis Based on Mean Time Between Failure (MTBF) Mean Time To Repair (MTTR) and Availability Methods at PT. Pertamina Hulu Rokan Regional 1 Zone 1 Field Rantau. Journal of Mechanical Engineering and Fabrication , 3 (1), 12-14.

Amri, A., & Nurjaya, M. (2022). “Eighty, Twenty”: Building Organizational Culture by Applying the Pareto Principle at KSPPS Bakti Huria Syariah. Emik , 5 (2), 222-240.

Arif, A. (2025). Proposed Maintenance of Elbow Condenser of XYZ Steam Power Plant Using Reliability Centered Maintenance (RCM) and Age Replacement Methods (Doctoral dissertation, Islamic University of Indonesia).

Azizah, NA (2025). Maintenance Analysis Using Failure Mode And Effects Analysis (FMEA) and Reliability Centered Maintenance (RCM) Methods (Case Study: PT. Chandra Asri Petrochemical Tbk) (Doctoral dissertation, Islamic University of Indonesia).

Bangun, C., Jalil, A., Amperajaya, D., & Rasjidin, R. (2022). Preventive maintenance scheduling with age replacement method at CNG station. Aptisi Transactions on Technopreneurship (ATT) , 4 (2), 153-163.

Heizer, J., Render, B., & Munson, C. (2017). Operations Management: Sustainability and Supply Chain Management (12th ed.). Pearson Education.

Jin, T. (2019). Reliability engineering and services . John Wiley & Sons.

Jovany, KCS, Thambas, AH, & Malingkas, GY (2025). Material Control in Construction Projects Using EOQ (Economic Order Quantity), POQ (Periodic Order Quantity), JIT (Just In Time) Methods. Journal of Syntax Literate , 10 (2).

Lebeheria, SASF (2025). Analysis of Coal Feeder Machine Maintenance System Planning to Improve the Reliability of Boiler Units 1-4 Using the Reliability Centered Maintenance (RCM) and Age Replacement Methods (Case Study: PT. PLN Indonesia Power UBP Suralaya) (Doctoral dissertation, Universitas Islam Indonesia).

Lemadi, G., Suroso, H., & Prasetio, DEA (2026). Reliability Analysis of Pallet Welding Machine Based on Reliability Centered Maintenance (RCM) and FMEA. RIGGS: Journal of Artificial Intelligence and Digital Business , 4 (4), 10956-10962.

Lestari, F. (2024). Application of Economic Order Quantity and Just in Time Methods to Improve Product Inventory Control Optimization. Bisnisman Journal: Business and Management Research , 5 (3), 35-56.

Molęda, M., Małysiak-Mrozek, B., Ding, W., Sunderam, V., & Mrozek, D. (2023). From corrective to predictive maintenance, A review of maintenance approaches for the power industry. Sensors , 23 (13), 5970.

Moubray, J. (1997). Reliability-Centered Maintenance. Butterworth-Heinemann

Purba, RS, & Rivani, R. (2025, October). Analysis of the Application of the EOQ Method in Inventory Management (Case Study at the Royal Folding Gate Jatinangor branch). In Entrepreneurship Business Forum (Vol. 15, No. 1, pp. 1-8).

Purnomo, DH (2025). The Effect of Scheduled Maintenance Management on Unit Damage Costs and Heavy Equipment Performance in the Indonesian Mining Industry. Journal of Locus Research and Community Service , 4 (12), 11255-11265.

Rinoza, M., & Ahmad Kurniawan, F. (2021). Analysis of Rpn (Risk Priority Number) on the Reliability of Double Screw Compressor Machine Components Using the FMEA Method at the Cement Factory of PT. Xyz. Xyz. Print) Buletin Utama Teknik , 17 (1), 1410-4520.

Ristono, A. (2013). Inventory Management . Yogyakarta: Graha Ilmu.

Sadewa, A., & Fragastia, VA (2025, December). Analysis of Boiler Machine Maintenance Using the RCM (Reliability Centered Maintenance) Method at PTPN IV Regional 1 PKS Sisumut Unit. In PROCEEDINGS OF THE NATIONAL MULTI-DISCIPLINARY SCIENCE SEMINAR (SENADIMU) (Vol. 2, No. 1, pp. 294-307).