NCREASE PHISICAL AVAILABILITY OF KOMATSU DOZZER D65P-12 LGP USING FMEA AT MINING NICKEL PT XYZ

Abstract

The Komatsu Dozer D65P-12 LGP at PT XYZ’s nickel mining site often failed to reach the 80% physical availability (PA) target due to frequent undercarriage failures. This study aimed to improve the unit’s availability using FMEA, supported by DMAIC, Why-Why Analysis, 5W2H, and other reliability tools. The improvement program was carried out in two phases: January–December 2024 and February–May 2025. Main initiatives included mechanical modifications, structured undercarriage inspections, backlog management, and improved preventive maintenance. The results showed strong progress: PA increased from 72% to 85%, backlog completion rose from 19% to 75%, and undercarriage downtime dropped from 82.4% to 58.9%. Specific actions, such as sprocket bolt modifications (reducing failures from 128 to 6) and carrier roller reworks (from 9 to 3), effectively minimized recurring issues. Overall, this study proves that data-driven and failure-focused maintenance can significantly improve equipment availability in mining operations, while also offering useful insights for practitioners and future research.