Implementation of ISMO – Based Maintenance System for Shaker Machines at PT X

Abstract

This study examines the implementation of the ISMO maintenance system (Inspection, Small Repair, Medium Repair, and Overhaul) for tobacco screening machines at PT X, located in East Java. The research compares the existing preventive maintenance approach with the ISMO method to evaluate differences in downtime and availability values. The screening machine, developed internally by PT X's engineering team, operates with vertical and horizontal movements to separate non-tobacco materials during processing. Using repair complexity analysis, the study determined the screening machine has a complexity value of 9 as a machine tool. Results indicate that the current company maintenance system achieves 99.86% availability with a total downtime of 580 minutes, whereas the ISMO method results in 97.89% availability with 8,856 minutes of downtime. The ISMO approach requires 3 workers for inspection, 8 for small repairs, 10 for medium repairs, and 11 for overhaul activities. While both methods show excellent availability above 95%, implementing ISMO significantly increases downtime, potentially causing production delays. This study provides a detailed classification of maintenance activities for each ISMO level, offering practical guidance for systematic machine maintenance implementation.