Root Cause Analysis and Repair Strategy for Cake Breaker Conveyor Damage in a Palm Oil Mill
Keywords:
Cake Breaker Conveyor, Fault Tree Analysis, Palm Oil Mill, Root Cause AnalysisAbstract
Unplanned breakdowns of the Cake Breaker Conveyor (CBC) can halt the kernel station of a palm oil mill. Previous CBC research addressed spare-part planning, whereas this study traces the root causes of CBC damage and converts them into measurable repair actions derived from minimum cut sets. A descriptive-qualitative case study was conducted at PT Socfindo Kebun Bangun Bandar using semi-structured interviews with workshop mechanics, technicians and CBC operators, direct observation, and breakdown records for November 2023–January 2024. Twelve damage events were recorded; broken conveyor pins (50.0%) and CBC pipe replacement (33.3%) accounted for 83.3% of them. Fault Tree Analysis (FTA) linked four damage types through one OR gate and two AND gates to six basic events and four minimum cut sets: bearing service life, shaft service life, a third-order combination of excessive raw-material load, repair-schedule clashes and unstable machine pressure, and pipe corrosion. Six 5W+1H strategies, each with a measurable indicator, were formulated: scheduled bearing and shaft replacement, capacity control, repair scheduling, pressure monitoring and pipe inspection. The results offer an evidence-based basis for shifting CBC maintenance from corrective to preventive practice.
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