Sensorisasi dan predictive maintenance untuk produsen otomotif tier-1Sensorization and predictive maintenance for a tier-1 automotive supplier
KonteksContext
Produsen komponen otomotif tier-1 dengan tiga pabrik di Jawa Barat menghadapi unplanned downtime yang merugikan, terutama pada mesin stamping dan welding kritis. Setiap jam downtime senilai ~USD 8.000.A tier-1 automotive component manufacturer with three West Java plants faced costly unplanned downtime, especially on critical stamping and welding machines. Each downtime hour cost ~USD 8,000.
Tantangan UtamaPrimary Challenges
- Unplanned downtime tinggi pada mesin kritisHigh unplanned downtime on critical machines
- Maintenance crew terbatas; pemeliharaan reaktifLimited maintenance crew; reactive maintenance
- Data sensor belum dimanfaatkan untuk prediksiSensor data not yet utilized for prediction
- Skeptisisme tim setelah dua proyek serupa gagalTeam skepticism after two similar projects failed
PendekatanApproach
Pemetaan Biaya Downtime (Bulan 1)Downtime Cost Mapping (Month 1)
Hitung biaya downtime per mesin per jam dalam kolaborasi finance + maintenance. Identifikasi 84 mesin kritis (threshold >USD 5.000/jam).Calculate downtime cost per machine per hour in finance + maintenance collaboration. Identify 84 critical machines (threshold >USD 5,000/hour).
Instalasi Sensor (Bulan 2–3)Sensor Installation (Months 2–3)
Instalasi sensor vibrasi, akustik, dan suhu pada 84 mesin. Validasi data stream ke cloud lakehouse.Vibration, acoustic, and temperature sensor installation on 84 machines. Validate data streams to cloud lakehouse.
Baseline & Model (Bulan 4–9)Baseline & Model (Months 4–9)
Pengumpulan baseline data selama 6 bulan. Pengembangan model ML production-ready, dilatih ulang setiap minggu.6-month baseline data collection. Production-ready ML model development, retrained weekly.
Integrasi Workflow (Bulan 10–12)Workflow Integration (Months 10–12)
Integrasi alert ke work order system & mobile app teknisi. Pelatihan 24 teknisi. Dashboard supervisor & eksekutif.Alert integration to work order system & technician mobile app. Training for 24 technicians. Supervisor & executive dashboards.
Hasil TerukurMeasurable Outcomes
Diskusi pendekatan serupa untuk organisasi AndaDiscuss similar approach for your organization
Detail engagement dapat dibagikan lebih lanjut setelah kesepakatan kerahasiaan.Engagement details can be shared further after a confidentiality agreement.