E-ISSN: 2963-3699
P-ISSN: 2964-0121
Homepage: Homepage: https://return.publikasikupublisher.com
This work is licensed under CC BY-SA 4.0
ANALYSIS OF ENGINE MAINTENANCE TECHNIQUES IN DOUBLE-CABIN
VEHICLE UNITS USING MODULARITY DESIGN METHOD AT PT WAHYU
PUTRA MANDIRI PERKASA
Tsabita Chaerunisa Tandriajeng1, Wiwik Handayani2*
Faculty of Economic and Business, "Veteran" National Development University, Surabaya, Indonesia1,2
tsabitaht.07@gmail.com1, wiwik.em@upnjatim.ac.id2
ABSTRACT
Companies that providing motorised vehicle rental services specialising in coal mining areas have to go
the extra mile in carrying out maintenance due to unexpected damage by the maintenance schedule. This
research aims to discover problems related to constraints on the maintenance system carried out so that
it is less efficient and effective in its implementation. Preventive maintenance with a modularity design
method collects data with documentation, interviews, and observations. The analysis technique
determines the company’s total cost (Initial TC). It continues determining the total cost of the proposal
(Proposed TC) which is processed using app. Minitab 2021. The results of this study indicate that
maintenance costs using preventive maintenance with the modularity design method are lower and more
efficient than maintenance costs using corrective maintenance carried out by the company.
Keywords: Corrective Maintenance; Double Cabin; Modularity Design; Preventive Maintenance
INTRODUCTION
The use of motorized vehicles in coal mining areas is very important in carrying out the process of
operational activities of mining industry companies (Abuya, 2016). The reason mining industry companies
choose to lease motorized vehicles for their operational cars is to avoid depreciation of asset values, free
maintenance costs, and availability of replacement units (Trac, 2023).
In the operational activities of mining industry companies, it provide its own challenges in
maintaining the vehicles used (Wilhelms et al., 2017). Not a few motorized vehicle units experience heavy
damage due to overuse and/or heavy use in the mining environment where the road terrain is muddy when
it rains and dusty and gravel (Hadi, 2019; Harada, 2020). Finally, companies providing motorized vehicle
rental services specifically for coal mining areas have to work extra in carrying out maintenance due to
damage that is not expected according to the maintenance schedule (Ciliberti et al., 2008; Shaheen & Chan,
2016). Maintenance is any activity such as tests, measurements, replacements, adjustments, and repairs
intended to maintain or restore a functional unit in or to a state where it can perform its required function
(Gortney, 2016). Poor maintenance can be disruptive, inconvenient, wasteful, and very costly, even
exceeding the cost of living (Besterfield et al., 2019; Heizer et al., 2020). With good maintenance, the tools,
objects and systems are always in a controlled condition and ready to be used at any time. With this
maintenance effort, in addition to ensuring that the goods are ready for use, it will also extend the life of
the equipment, goods or system (Taufiqullah, 2022).
In performing the maintenance system required grouping damage to the sub-components of the
machine based on the function and process (Tan et al., 2011; Villarini et al., 2017). This grouping can be
determined through the Modularity Design method. Modularity Design is a preventive maintenance method
that aims to combine several machine components into a maintenance module (Putri et al., 2020; Yanti,
2015). The application of the Modularity Design method by grouping components based on into certain
modules in the hope that it can facilitate the replacement of machine components, ten maintenance time,
and reduce maintenance costs at the company (Daruhadi et al., 2023; Suwondo & Widjajati, 2020).
Modularity allows for a reduction in service costs by grouping components based on similarities and
dependencies. Some companies apply modularity design to facilitate the grouping of components/sub-
components when performing periodic maintenance which aims to reduce maintenance costs and reduce
the occurrence of damage. One example is PT RAJA Beton Indonesia, a batching plant machine that
previously carried out maintenance using the breakdown maintenance method to preventive maintenance
which greatly reduced previous maintenance costs. PT Wahyu Putra Mandiri Perkasa (PT WPMP) has a
double cabin vehicle unit that is chosen by mining companies as an operational vehicle because its function
is in accordance with the needs of the company. This study aims to determine the problems related to
constraints on the maintenance system carried out so that it is less efficient and effective in its
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
900 Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
implementation and determine maintenance scheduling/planning with the modularity design approach
method in order to produce efficient maintenance costs for double cabin vehicle units at PT WPMP.
RESEARCH METHOD
The research method used in this research is a descriptive quantitative method with the aim of
describing and explaining an event accurately and systematically about the facts in the phenomenon under
study (Priadana & Sunarsi, 2021; Yilmaz, 2013). The research was taken in Balikpapan City from May
2021 until April 2022. The population and sample were 13 units of double-cabin cars. Data collecting
techniques by interview with the mechanics and secondary data from the company such as list of the
vehicles and record notes of maintenance. Data analysis techniques are: the first research method is to
calculate maintenance costs by the company; second, grouping sub-components into modules; third,
Weibull distribution suitability test; fourth, calculate MTTR and MTTF; fifth, calculate maintenance and
damage costs; sixth, calculate total proposed maintenance costs; seventh, comparison between initial
maintenance costs and proposed maintenance costs (Díaz-Reza et al., 2019).
RESULT AND DISCUSSION
Company Maintenance Cost / Initial Total Cost
1. Component Maintenance Cost
The company performs maintenance on a scheduled basis, but due to road conditions,
weather, and several other factors cause damage to occur more quickly or unexpectedly. Based
on information data from the company, component maintenance costs can be seen in table 1 below.
Table 1 Maintenance Cost Data in the Company
Component
Sub-Component
Maintenance Cost
(May 2021-April 2022)
ENGINE
Engine Oil
Rp 2,640,000
Oil Filter
Rp 1,020,000
Fuel Filter
Rp 500,000
Air Filter
Rp 810,000
Air Radiator
Rp 290,000
Timing Belt
Rp 450,000
STEERING
SYSTEM
Steering Oil
Rp 504,000
Bearing Roda Depan
Rp 1,050,000
Tie Rod
Rp 1,000,000
BRAKING
SYSTEM
Disc Brake
Rp 2,260,000
Brake Pad
Rp 300,000
Brake Shoe
Rp 1,400,000
Drum Brake
Rp 1,200,000
Master Brake
Rp 1,500,000
Minyak Rem
Rp 160,000
POWER
TRAIN
Oli Transmisi
Rp 240,000
Oli Gardan
Rp 370,000
BATTERY &
ELECTRICAL
SYSTEM
Air ACCU
Rp 165,000
ACCU
Rp 1,050,000
Head Lamp
Rp 360,000
Fog Lamp
Rp 150,000
Reverse Lamp
Rp 1,800,000
Back Alarm
Rp 300,000
Lampu Rotari
Rp 4,800,000
Brake Lamp
Rp 100,000
Lampu Sein
Rp 40,000
WHEEL,
SUSPENSION
Ban Kendaraan
Rp 1,350,000
Shock Absorber
Rp 475,000
Spring / Per
Rp 750,000
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
901
Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
TOTAL
Rp 27,034,000
The data is obtained from the company and is the real data of the company's maintenance costs for
the period May 2021 to April 2022.
2. Calculation of Downtime Costs and Labor Costs
Based on the data collected, the calculation of labor costs and downtime costs can be seen in
the table 2. Table 2 Disadvantages of Each Component
Component
Tanggal
Kerugian Akibat
Downtime
Biaya Mekanik
Engine
03/05/2021
Rp 31,944
Rp 21,485
Engine
03/05/2021
Rp 31,944
Rp 14,323
Engine
07/05/2021
Rp 31,944
Rp 21,485
Steering System
19/05/2021
Rp 31,944
Rp 42,969
Steering System
31/05/2021
Rp 31,944
Rp 85,938
Battery & Electrical System
31/05/2021
Rp 31,944
Rp 14,323
Engine
04/06/2021
Rp 31,944
Rp 21,485
Battery & Electrical System
04/06/2021
Rp 31,944
Rp 21,485
Steering System
16/06/2021
Rp 31,944
Rp 42,969
Battery & Electrical System
18/06/2021
Rp 31,944
Rp 14,323
Wheel, Suspension
18/06/2021
Rp 31,944
Rp 85,938
Engine
30/06/2021
Rp 31,944
Rp 14,323
Engine
01/07/2021
Rp 31,944
Rp 21,485
Battery & Electrical System
01/07/2021
Rp 31,944
Rp 14,323
Engine
06/07/2021
Rp 31,944
Rp 21,485
Steering System
13/07/2021
Rp 31,944
Rp 42,969
Braking System
06/08/2021
Rp 31,944
Rp 85,938
Braking System
06/08/2021
Rp 31,944
Rp 85,938
Braking System
09/08/2021
Rp 31,944
Rp 85,938
Braking System
09/08/2021
Rp 31,944
Rp 42,969
Power Train
09/08/2021
Rp 31,944
Rp 14,323
Power Train
09/08/2021
Rp 31,944
Rp 14,323
Engine
09/08/2021
Rp 31,944
Rp 21,485
Engine
09/08/2021
Rp 31,944
Rp 14,323
Engine
09/08/2021
Rp 31,944
Rp 14,323
Steering System
14/08/2021
Rp 31,944
Rp 42,969
Battery & Electrical System
14/08/2021
Rp 31,944
Rp 14,323
Steering System
03/09/2021
Rp 31,944
Rp 42,969
Battery & Electrical System
11/09/2021
Rp 31,944
Rp 14,323
Battery & Electrical System
15/09/2021
Rp 31,944
Rp 14,323
Engine
16/09/2021
Rp 31,944
Rp 21,485
Engine
16/09/2021
Rp 31,944
Rp 21,485
Battery & Electrical System
16/09/2021
Rp 31,944
Rp 14,323
Battery & Electrical System
25/09/2021
Rp 31,944
Rp 14,323
Battery & Electrical System
25/09/2021
Rp 31,944
Rp 21,485
Engine
13/10/2021
Rp 31,944
Rp 21,485
Engine
13/10/2021
Rp 31,944
Rp 14,323
Braking System
16/10/2021
Rp 31,944
Rp 85,938
Braking System
16/10/2021
Rp 31,944
Rp 85,938
Wheel, Suspension
16/10/2021
Rp 31,944
Rp 85,938
Steering System
17/10/2021
Rp 31,944
Rp 42,969
Battery & Electrical System
17/10/2021
Rp 31,944
Rp 14,323
Steering System
02/11/2021
Rp 31,944
Rp 42,969
Engine
09/11/2021
Rp 31,944
Rp 14,323
Engine
13/11/2021
Rp 31,944
Rp 21,485
Engine
13/11/2021
Rp 31,944
Rp 21,485
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
902 Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
Steering System
13/11/2021
Rp 31,944
Rp 42,969
Battery & Electrical System
15/11/2021
Rp 31,944
Rp 14,323
Steering System
19/11/2021
Rp 31,944
Rp 85,938
Battery & Electrical System
19/11/2021
Rp 31,944
Rp 14,323
Battery & Electrical System
19/11/2021
Rp 31,944
Rp 14,323
Wheel, Suspension
03/12/2021
Rp 31,944
Rp 85,938
Braking System
03/12/2021
Rp 31,944
Rp 42,969
Engine
06/12/2021
Rp 31,944
Rp 21,485
Battery & Electrical System
11/12/2021
Rp 31,944
Rp 14,323
Steering System
25/12/2021
Rp 31,944
Rp 42,696
Engine
25/12/2021
Rp 31,944
Rp 85,938
Steering System
27/12/2021
Rp 31,944
Rp 42,969
Engine
27/12/2021
Rp 31,944
Rp 14,323
Battery & Electrical System
04/01/2022
Rp 31,944
Rp 14,323
Engine
07/01/2022
Rp 31,944
Rp 21,485
Battery & Electrical System
14/01/2022
Rp 31,944
Rp 14,323
Braking System
18/01/2022
Rp 31,944
Rp 85,938
Braking System
18/01/2022
Rp 31,944
Rp 85,938
Braking System
18/01/2022
Rp 31,944
Rp 85,938
Battery & Electrical System
18/01/2022
Rp 31,944
Rp 14,323
Engine
20/01/2022
Rp 31,944
Rp 21,485
Engine
02/02/2022
Rp 31,944
Rp 21,485
Engine
04/02/2022
Rp 31,944
Rp 14,323
Steering System
11/02/2022
Rp 31,944
Rp 85,938
Steering System
25/02/2022
Rp 31,944
Rp 42,969
Battery & Electrical System
25/02/2022
Rp 31,944
Rp 14,323
Engine
01/03/2022
Rp 31,944
Rp 21,485
Engine
01/03/2022
Rp 31,944
Rp 21,485
Engine
01/03/2022
Rp 31,944
Rp 14,323
Braking System
01/03/2022
Rp 31,944
Rp 42,969
Power Train
01/03/2022
Rp 31,944
Rp 14,323
Power Train
01/03/2022
Rp 31,944
Rp 14,323
Engine
02/03/2022
Rp 31,944
Rp 14,323
Battery & Electrical System
02/03/2022
Rp 31,944
Rp 14,323
Battery & Electrical System
05/03/2022
Rp 31,944
Rp 21,485
Battery & Electrical System
08/03/2022
Rp 31,944
Rp 14,323
Steering System
10/03/2022
Rp 31,944
Rp 42,969
Battery & Electrical System
14/03/2022
Rp 31,944
Rp 14,323
Wheel, Suspension
14/03/2022
Rp 31,944
Rp 42,969
Battery & Electrical System
18/03/2022
Rp 31,944
Rp 14,323
Battery & Electrical System
18/03/2022
Rp 31,944
Rp 14,323
Battery & Electrical System
27/03/2022
Rp 31,944
Rp 14,323
Battery & Electrical System
14/04/2022
Rp 31,944
Rp 14,323
Battery & Electrical System
14/04/2022
Rp 31,944
Rp 14,323
Battery & Electrical System
16/04/2022
Rp 31,944
Rp 21,485
Steering System
20/04/2022
Rp 31,944
Rp 42,969
Braking System
25/04/2022
Rp 31,944
Rp 42,969
Braking System
28/04/2022
Rp 31,944
Rp 85,938
Braking System
28/04/2022
Rp 31,944
Rp 85,938
TOTAL
Rp 3,034,680
Rp 3,243,897
Source: Data Processing
In table 2, that the loss due to downtime experienced by the company during the period
May 2021-April 2022 was IDR 3,034,680, - and mechanical costs of IDR 3,243,897.
So that the results of the calculation of the total cost of company maintenance (Initial TC)
are as follows:
Initial TC = Total Maintenance Cost + Downtime Losses + Mechanical Costs
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
903
Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
= Rp 27.034.000 + Rp 3.034.680 + Rp 3.243.897
= Rp 33.312.577,-
Maintenance Cost Calculation with Modularity Design Method
To calculate maintenance costs using the modularity design method or the proposed TC.
1. Grouping Critical Components According to Modularity Design
The following is a grouping of critical components into several modules according to the
layout/position of machine repair. For more details can be seen in Table 3.
Table 3 Data Grouping by Module
Module
Sub-components (components)
Module 1
Engine Oil (Engine)
Oil Filter (Engine)
Fuel Filter (Engine)
Air Filter (Engine)
Air Radiator (Engine)
Timing Belt (Engine)
Oli Transmisi (Power Train)
Oli Gardan (Power Train)
Module 2
Steering Oil (Steering System)
Bearing Roda Depan (Steering System)
Tie Rod (Steering System)
Ban Kendaraan (Wheel, Suspension)
Shock Absorber (Wheel, Suspension)
Spring / Per (Wheel, Suspension)
Module 3
Air ACCU (Battery & Electrical System)
ACCU (Battery & Electrical System)
Head Lamp (Battery & Electrical System)
Fog Lamp (Battery & Electrical System)
Reverse Lamp (Battery & Electrical System)
Back Alarm (Battery & Electrical System)
Lampu Rotari (Battery & Electrical System)
Brake Lamp (Battery & Electrical System)
Lampu Sein (Battery & Electrical System)
Module 4
Disc Brake (Braking System)
Brake Pad (Braking System)
Brake Shoe (Braking System)
Drum Brake (Braking System)
Master Brake (Braking System)
Minyak Rem (Braking System)
Source: Data Processing
2. Test for Distribution Conformity of Damage Data
The following is the data that has been grouped for each module which is displayed in table 4.
Table 4 Grouping Data by Module
Module
Sub-
Component
Downtime
(Minute)
Time Between
Breakdowns
(Minute)
Module
1
Oil Filter
15
-
15
84,960
15
109,440
15
83,520
15
97,920
15
57,600
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
904 Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
Engine Oil
15
-
15
40,320
15
46,080
15
48,960
15
54,720
15
38,880
15
44,640
15
34,560
15
46,080
15
37,440
15
38,880
Fuel Filter
10
-
10
141,120
10
132,480
10
161,280
Air Filter
10
-
10
57,600
10
93,600
10
108,000
10
56,160
Air Radiator
10
-
Timing Belt
60
-
Oli Transmisi
10
-
10
293,760
Oli Gardan
10
-
10
293,760
Module
2
Steering Oil
30
-
30
84,960
30
28,800
30
63,360
30
38,880
30
63,360
30
86,400
30
18,720
30
59,040
Bearing Roda
Depan
60
-
60
247,680
60
120,960
Tie Rod
30
-
30
79,200
30
161,280
30
77,760
Spring
60
-
60
241,920
Shock Absorber
60
-
Vehicle Tires
30
-
Module
3
Air ACCU
10
-
10
25,920
10
18,720
10
63,360
10
47,520
10
44,640
10
47,520
10
31,680
10
48,960
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
905
Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
10
60,480
10
24,480
ACCU
15
-
Head Lamp
10
-
10
165,600
10
123,840
Fog Lamp
10
-
10
277,920
Reverse Lamp
10
-
10
256,320
10
53,280
Back Alarm
10
-
10
154,080
Rotary Light
15
-
15
231,840
15
60,480
Brake Lamp
10
-
10
105,120
Turn Signal
10
-
10
171,360
Module
4
Disc Brake
60
-
60
233,280
Brake Pad
60
-
60
279,360
Brake Shoe
60
-
60
102,240
60
135,360
60
144,000
Drum Brake
60
-
60
237,600
Master Brake
30
-
30
205,920
Brake Fluid
30
-
30
293,760
Furthermore, the distribution test was carried out using app. Minitab 2021. The following
are the results of distribution testing on individual modules.
Table 5 Distribution Test Results Based on Downtime Data
Component
Type of
Distribution
Parameter
β (shape)
η (scale)
Module 1
Weibull
1,83502
16,0865
Module 2
Weibull
3,02398
43,7987
Module 3
Weibull
5,43491
11,4742
Module 4
Weibull
5,24138
56,3823
Source: Data Processing with Minitab App 2021
The table above is the result of data processing carried out with App Minitab 2021.
Parameter values are obtained by looking at the estimate value in the distribution test. The shape
parameter (β) describes the shape of the Weibull distribution. While the scale parameter (η)
describes the distribution of data on the Weibull distribution and is also displayed in table 6.
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
906 Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
Table 6 Distribution Test Results Based on Time Between Damages
Komponen
Jenis
Distribusi
Parameter
β (shape)
η (scale)
Modul 1
Weibull
1,48275
102.745
Modul 2
Weibull
1,51913
109.535
Modul 3
Weibull
1,33427
110.284
Modul 4
Weibull
3,60585
227.301
Source: Data Processing with Minitab App 2021
3. MTTR and MTTF Calculations
After obtaining the distribution and parameters of each distribution, then the calculation of
Mean Time To Repair (MTTR) and Mean Time To Failure (MTTF) can be done using the formula
MTTR/MTTF = 󰇛
󰇜 (Ebeling 2019).
Table 7 MTTR dan MTTF Calculation Result
MODUL
MTTR
MTTF
1
14,2930 menit
92.885,9 menit
2
39,1251 menit
98.734,3 menit
3
10,5858 menit
101.345 menit
4
51,9093 menit
204.840 nit
Source: Data Processing
4. Calculation of Component Replacement Cost Due to Maintenance (Cp) and Component
Replacement Cost Due to Damage (Cf)
Calculation of component costs due to maintenance includes mechanical costs and the price
of each component. The following Cp calculations for each module can be seen in Table 8:
Table 8 Component Replacement Cost Due to Maintenance (Cp)
Module
Sub- Component (Component)
MTTR
(Minute)
Cp
Total of
Damages
Total Cp
Module 1
Engine Oil (Engine)
14.293
Rp 246,824
11
Rp 2,715,064
Oil Filter (Engine)
14.293
Rp 176,824
6
Rp 1,060,944
Fuel Filter (Engine)
14.293
Rp 131,824
4
Rp 527,296
Air Filter (Engine)
14.293
Rp 168,824
5
Rp 844,120
Air Radiator (Engine)
14.293
Rp 296,824
1
Rp 296,824
Timing Belt (Engine)
14.293
Rp 456,824
1
Rp 456,824
Oli Transmisi (Power Train)
14.293
Rp 126,824
2
Rp 253,648
Oli Gardan (Power Train)
14.293
Rp 191,824
2
Rp 383,648
TOTAL
Rp 6,538,368
Module 2
Steering Oil (Steering System)
39.1251
Rp 62,108
9
Rp 558,972
Bearing Roda Depan (Steering System)
39.1251
Rp 356,108
3
Rp 1,068,324
Tie Rod (Steering System)
39.1251
Rp 256,108
4
Rp 1,024,432
Ban Kendaraan (Wheel, Suspension)
39.1251
Rp 1,356,108
1
Rp 1,356,108
Shock Absorber (Wheel, Suspension)
39.1251
Rp 481,108
1
Rp 481,108
Spring / Per (Wheel, Suspension)
39.1251
Rp 381,108
2
Rp 762,216
TOTAL
Rp 5,251,160
Module 3
Air ACCU (Battery & Electrical System)
10.5858
Rp 20,054
11
Rp 220,594
ACCU (Battery & Electrical System)
10.5858
Rp 1,055,054
1
Rp 1,055,054
Head Lamp (Battery & Electrical System)
10.5858
Rp 125,054
3
Rp 375,162
Fog Lamp (Battery & Electrical System)
10.5858
Rp 80,054
2
Rp 160,108
Reverse Lamp (Battery & Electrical System)
10.5858
Rp 605,054
3
Rp 1,815,162
Back Alarm (Battery & Electrical System)
10.5858
Rp 155,054
2
Rp 310,108
Lampu Rotari (Battery & Electrical System)
10.5858
Rp 1,605,054
3
Rp 4,815,162
Brake Lamp (Battery & Electrical System)
10.5858
Rp 55,054
2
Rp 110,108
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
907
Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
Lampu Sein (Battery & Electrical System)
10.5858
Rp 25,054
2
Rp 50,108
TOTAL
Rp 8,911,566
Module 4
Disc Brake (Braking System)
51.9093
Rp 1,154,783
2
Rp 2,309,566
Brake Pad (Braking System)
51.9093
Rp 174,783
2
Rp 349,566
Brake Shoe (Braking System)
51.9093
Rp 374,783
4
Rp 1,499,132
Drum Brake (Braking System)
51.9093
Rp 624,783
2
Rp 1,249,566
Master Brake (Braking System)
51.9093
Rp 774,783
2
Rp 1,549,566
Minyak Rem (Braking System)
51.9093
Rp 104,783
2
Rp 209,566
TOTAL
Rp 7,166,962
Source: Data Processing (2022)
The calculation of component costs due to maintenance includes mechanical costs, costs of losses
due to downtime and the price of each component where all of these costs are losses caused by component
damage. The following Cf calculations for each module can be seen in table 9.
Table 9 Cost of replacing parts due to damage (Cf)
Module
Sub-Component (Component)
MTTR
(Minute)
Cf
Total of
Damages
Total Cf/ Sub-
Component
Module
1
Engine Oil (Engine)
14.293
Rp 254,434
11
Rp 2,798,774
Oil Filter (Engine)
14.293
Rp 184,434
6
Rp 1,106,604
Fuel Filter (Engine)
14.293
Rp 139,434
4
Rp 557,736
Air Filter (Engine)
14.293
Rp 176,434
5
Rp 882,170
Air Radiator (Engine)
14.293
Rp 304,434
1
Rp 304,434
Timing Belt (Engine)
14.293
Rp 464,434
1
Rp 464,434
Oli Transmisi (Power Train)
14.293
Rp 134,434
2
Rp 268,868
Oli Gardan (Power Train)
14.293
Rp 199,434
2
Rp 398,868
TOTAL
Rp 6,781,888
Module
2
Steering Oil (Steering System)
39.1251
Rp 68,920
9
Rp 620,280
Bearing Roda Depan (Steering System)
39.1251
Rp 362,920
3
Rp 1,088,760
Tie Rod (Steering System)
39.1251
Rp 262,920
4
Rp 1,051,680
Ban Kendaraan (Wheel, Suspension)
39.1251
Rp 1,362,920
1
Rp 1,362,920
Shock Absorber (Wheel, Suspension)
39.1251
Rp 487,920
1
Rp 487,920
Spring / Per (Wheel, Suspension)
39.1251
Rp 387,920
2
Rp 775,840
TOTAL
Rp 5,387,400
Module
3
Air ACCU (Battery & Electrical System)
10.5858
Rp 25,690
11
Rp 282,590
ACCU (Battery & Electrical System)
10.5858
Rp 1,060,690
1
Rp 1,060,690
Head Lamp (Battery & Electrical System)
10.5858
Rp 130,690
3
Rp 392,070
Fog Lamp (Battery & Electrical System)
10.5858
Rp 85,690
2
Rp 171,380
Reverse Lamp (Battery & Electrical System)
10.5858
Rp 610,690
3
Rp 1,832,070
Back Alarm (Battery & Electrical System)
10.5858
Rp 160,690
2
Rp 321,380
Lampu Rotari (Battery & Electrical System)
10.5858
Rp 1,610,690
3
Rp 4,832,070
Brake Lamp (Battery & Electrical System)
10.5858
Rp 60,690
2
Rp 121,380
Lampu Sein (Battery & Electrical System)
10.5858
Rp 30,690
2
Rp 61,380
TOTAL
Rp 9,075,010
Module
4
Disc Brake (Braking System)
51.9093
Rp 1,182,420
2
Rp 2,364,840
Brake Pad (Braking System)
51.9093
Rp 202,420
2
Rp 404,840
Brake Shoe (Braking System)
51.9093
Rp 402,420
4
Rp 1,609,680
Drum Brake (Braking System)
51.9093
Rp 652,420
2
Rp 1,304,840
Master Brake (Braking System)
51.9093
Rp 802,420
2
Rp 1,604,840
Minyak Rem (Braking System)
51.9093
Rp 132,420
2
Rp 264,840
TOTAL
Rp 7,553,880
Source: Data Processing
5. Calculating maintenance time intervals
Calculations for this maintenance time interval include replacement costs due to maintenance
(Cp), component replacement costs due to damage (Cf), scale values, and shape values at the time
between treatments. The value of TM in each module can be seen in table 10 below.
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
908 Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
Table 10 Maintenance Interval Time (TM)
Modules
Parameters
β (shape)
Parameters
η (scale)
Cp
Cf
TM
(Minutes)
1
1,48275
102.745
Rp 6.538.368
Rp 6.781.874
163.815,670
2
1,51913
109.535
Rp 5.251.160
Rp 5.387.396
165.827,344
3
1,33427
110.284
Rp 8.911.566
Rp 9.075.007
247.328,033
4
3,60585
227.301
Rp 7.166.962
Rp 7.553.876
171.757,060
Source: Data Processing
6. Calculation of Total Maintenance Costs Using the Modularity Design Method
The total maintenance cost is calculated according to the unit of time used. Because the data
above uses units of minutes, then based on Weibull-distributed data, the total maintenance cost is
shown in Table 11.
Table 11 Recapitulation of TC Calculation per Module
Modules
TC (Rp/min)
1
Rp 123/minute
2
Rp 93/ minute
3
Rp 144/ minute
4
Rp 58/ minute
Source: Data Processing
The total maintenance costs per year are shown in Table 12 below.
Table 12 Calculation of Total Cost per 1 Year Using Modularity Design
Modules
Total Cost (Rupiah/ 1 Year)
1
Rp 6.500.500
2
Rp 5.359.658
3
Rp 8.858.943
4
Rp 6.948.986
Total
Rp 27.668.087
Choosing a Maintenance Method with Minimum Cost
Based on the calculation results, the next treatment comparison can be calculated in table
13 as follows:
Table 13 Comparison of Total Maintenance
Cost of The Company and Modularity Design
Company’s Total Maintenance Cost
Total Cost with Modularity of Design
Rp 33.312.577,-/1 tahun
Rp 27.577.211,-/1 tahun
Source: Data Processing
From table 13 above, it can be seen that the total maintenance cost of the company is IDR
33,312,577 per 1 year. Meanwhile, the modularity design method resulted in a total maintenance
cost of Rp 27,577,211 per 1 year. The efficiency between maintenance costs in the company and
the proposed method can be calculated. The calculation is as follows:
Efficiency = 
 
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
909
Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
= 
 
= 17,22%
Discussion
Based on the data processing above, it can be seen that in operational maintenance
activities, vehicle units more often use corrective maintenance methods for most components.
Corrective Maintenance is maintenance that is carried out repeatedly or maintenance carried out
to repair a part (including adjustments and repairs) that has stopped to meet an acceptable
condition (Karabağ et al., 2020; Suzen & Feriadi, 2019).
The method used by the company currently still incurs considerable costs and requires other
alternative methods in order to minimize the costs incurred for maintenance activities. The
alternative method used in this study has been applied by the company, it's just very rare, namely
preventive maintenance. Preventive maintenance is maintenance that is carried out in a planned
manner to prevent potential damage from occurring which aims to minimize losses in production
time and large repair costs (Ansori & Mustajib, 2013). Modularity Design can be said to be more
efficient than other methods, because it specifically divides more complicated components into
more understandable parts, making maintenance more efficient and reducing the time needed to
complete it.
In this study, the proposed (TC) with the modularity design method has the lowest cost than
the initial (TC) with the method carried out by the company with an efficiency of 17.22% for the
period May 2021-April 2022. According to Subagja (Subagja, 2018) modularity design has
several advantages, namely easier design of new components, reduced maintenance labor training
costs and time, ease of maintenance, decreased maintenance time, low capability requirements
for moving modular units, and easier removal of failed units.
The results of this study indicate that the application of preventive maintenance through
the modularity design method can minimize total maintenance costs rather than corrective
maintenance carried out by the previous company. Preventive maintenance is an action that needs
to be taken by the company so that the vehicle engine is maintained, reliability is maintained and
stable, and can reduce maintenance costs (Afiva et al., 2019). The contribution of cost efficiency
by implementing preventive maintenance is that the economic life of engine components will be
more durable for the next 3 to 5 years.
CONCLUSION
Based on the results of the analysis conducted, the company more often conducts machine
maintenance activities using corrective maintenance which causes high-cost losses due to
component replacement after damage occurs. Whereas by implementing preventive maintenance
through the modularity design method, prevention before damage occurs and faster maintenance
is carried out can extend component life. So by implementing preventive maintenance, the costs
incurred are lower than corrective maintenance.
REFERENCES
Abuya, W. O. (2016). Mining conflicts and Corporate Social Responsibility: Titanium mining in
Kwale, Kenya. The Extractive Industries and Society, 3(2), 485–493.
https://doi.org/10.1016/j.exis.2015.12.008 Google Scholar
Afiva, W. H., Atmaji, F. T. D., & Alhilman, J. (2019). Penerapan Metode Reliability Centered
Maintenance (RCM) pada Perencanaan Interval Preventive Maintenance dan Estimasi Biaya
Pemeliharaan Menggunakan Analisis FMECA ( Studi Kasus : PT. XYZ). Jurnal PASTI
(Penelitian Dan Aplikasi Sistem Dan Teknik Industri), 13(3), 298–310. https://doi.org/2598-
4853 Google Scholar
Ansori, N., & Mustajib, M. I. (2013). Sistem Perawatan Terpadu. Graha Ilmu. Google Scholar
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
910 Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
Besterfield, D. H., Michna, C. B., Besterfield, G. H., Scare, M. B., Udhwareshe, H., &
Udhwareshe, R. (2019). Total Quality Management (Fifth Edision). Pearson India
Educational Pvt. Ldt. Google Scholar
Ciliberti, F., Pontrandolfo, P., & Scozzi, B. (2008). Logistics social responsibility: Standard
adoption and practices in Italian companies. International Journal of Production
Economics, 113(1), 88–106. https://doi.org/10.1016/j.ijpe.2007.02.049 Google Scholar
Daruhadi, G., Yuliati, E., Elgasari, F. M., Indradewa, R., & Negoro, D. A. (2023). Strategic
Formulation Analysis of Business Development of PT Mega Power Surya (A Subsidiary of
PT Mega Power Teknindo). Return: Study of Management, Economic and Bussines, 2(05),
526–542. https://doi.org/https://doi.org/10.57096/return.v2i05.108 Google Scholar
Díaz-Reza, J. R., Gracia-Alcaraz, & Loya, V. M. (2019). Impact Analysis of Total Productive
Maintenance-Critical Success Factors and Benefits. Springer Nature. Google Scholar
Ebeling, C. E. (2019). An Introduction To Reliability And Maintenance Engineering (3rd ed.).
Waveland Press, Incorporated. Google Scholar
Gortney, W. E. (2016). Department of Defense Dictionary of Military and Associated Terms.
United States Department of Defense. Google Scholar
Hadi, S. (2019). Perawatan dan Perbaikan Mesin Industri. Andi Offset. Google Scholar
Harada, M. K. (2020). Perawatan Mesin Batching Plant Secara Preventive dengan Metode
Modularity Design pada PT Restu Anak Jaya Abadi Beton Indonesia – Plant Osowilangun.
UPN “Veteran” Jawa Timur. Google Scholar
Heizer, J., Render, B., & Munson, C. (2020). Operations Management: Sustainability and Supply
Chain Management. Pearson Education London. Google Scholar
Karabağ, O., Eruguz, A. S., & Basten, R. (2020). Integrated optimization of maintenance
interventions and spare part selection for a partially observable multi-component system.
Reliability Engineering & System Safety, 200, 106955.
https://doi.org/10.1016/j.ress.2020.106955 Google Scholar
Priadana, S., & Sunarsi, D. (2021). Metode Penelitian Kuantitatif (1st ed.). Pascal Books. Google
Scholar
Putri, N. T., Taufik, & Buana, F. S. (2020). Preventive Maintenance Scheduling by Modularity
Design Applied to Limestone Crusher Machine. Procedia Manufacturing, 43, 682–687.
https://doi.org/10.1016/j.promfg.2020.02.123 Google Scholar
Shaheen, S., & Chan, N. (2016). Mobility and the Sharing Economy: Potential to Facilitate the
First- and Last-Mile Public Transit Connections. Built Environment, 42(4), 573–588.
https://doi.org/10.2148/benv.42.4.573 Google Scholar
Subagja, T. (2018). Analisis Perawatan Mesin Rolling Secara Berkala dengan Pendekatan
Modularisasi Desain. Seminar Nasional Teknologi, 172–177. Google Scholar
Suwondo, A. Z. Z., & Widjajati, E. P. (2020). Perawatan Mesin Mixer Secara Preventive dengan
Metode Modularity Design di PT XYZ. Juminten: Jurnal Manajemen Industri Dan
Teknologi, 1(52), 37–48. Google Scholar
Analysis of Engine Maintenance Techniques in Double-Cabin Vehicle Units Using Modularity Design
Method at PT Wahyu Putra Mandiri Perkasa
911
Return: Study of Management, Economic And Business, Vol 2 (9), September 2023
Suzen, Z. S., & Feriadi, I. (2019). Pembuatan Program Aplikasi Laporan Perawatan Korektif
Laboratorium Pemesinan Polman Babel. Manutech : Jurnal Teknologi Manufaktur, 10(01),
53–57. https://doi.org/10.33504/manutech.v10i01.59 Google Scholar
Tan, Z., Li, J., Wu, Z., Zheng, J., & He, W. (2011). An evaluation of maintenance strategy using
risk based inspection. Safety Science, 49(6), 852–860.
https://doi.org/10.1016/j.ssci.2011.01.015 Google Scholar
Taufiqullah, T. (2022). Pengertian Perawatan dan Perbaikan. TN Mesin.
https://www.tneutron.net/mesin/pengertian-perawatan-dan-perbaikan/ Google Scholar
Trac. (2023, January 27). Alasan Kenapa Perusahaan Tambang Sebaiknya Rental Mobil Untuk
Kendaraan Operasional. Trac Member of Astra.
https://www.trac.astra.co.id/blog/berita/alasan-kenapa-perusahaan-tambang-sebaiknya-
rental-mobil-untuk-kendaraan-operasional/466 Google Scholar
Villarini, M., Cesarotti, V., Alfonsi, L., & Introna, V. (2017). Optimization of photovoltaic
maintenance plan by means of a FMEA approach based on real data. Energy Conversion
and Management, 152, 1–12. https://doi.org/10.1016/j.enconman.2017.08.090 Google
Scholar
Wilhelms, M.-P., Merfeld, K., & Henkel, S. (2017). Yours, mine, and ours: A user-centric
analysis of opportunities and challenges in peer-to-peer asset sharing. Business Horizons,
60(6), 771–781. https://doi.org/10.1016/j.bushor.2017.07.004 Google Scholar
Yanti, V. T. (2015). Penerapan Preventive Maintenance dengan Menggunakan Metode
modularity Design pada Mesin Goss di PT.ABC [Tugas Akhir]. Institut Teknologi Sepuluh
Nopember. Google Scholar
Yilmaz, K. (2013). Comparison of Quantitative and Qualitative Research Traditions:
epistemological, theoretical, and methodological differences. European Journal of
Education, 48(2), 311–325. https://doi.org/10.1111/ejed.12014 Google Scholar