APPLICATION OF FMEA AND RCM IN DEVELOPING A STANDARD OPERATING PROCEDURE (SOP) FOR BELT CONVEYOR SPLICING

Abstract

Belt conveyors are the most widely used material transportation systems in various industries because they are capable of continuously moving goods efficiently and consistently. This system consists of a belt driven by pulleys and a motor, enabling the transfer of large quantities of material in a relatively short time. Its reliability is highly influenced by the quality of the belt joint, making maintenance and splicing procedures crucial aspects. This study discusses the application of Failure Mode and Effect Analysis (FMEA) and Reliability Centered Maintenance (RCM) methods in developing a Standard Operating Procedure (SOP) for belt conveyor splicing. The study was conducted at PT. Indonesia Belting Solution during the period of June 1 – July 31, 2025, through field observations, technical interviews, documentation, and data analysis. The results of the identification show that the dominant failures occur at the belt joints in the form of breakage, tearing, and brittleness. FMEA analysis indicates that joint failure due to inaccurate splicing processes is the top priority with the highest Risk Priority Number (RPN). Through the RCM approach, a Condition Directed Maintenance strategy was established as the primary action, and an SOP for splicing using the finger splice and hot press methods was developed to improve joint quality. In addition to providing a structured evaluation of potential failures, this study emphasizes that the integration of FMEA and RCM can serve as a systematic basis for preparing standard procedures. The proposed SOP implementation is expected to enhance joint strength, extend belt service life, and reduce production downtime, thereby improving conveyor system reliability and overall operational efficiency.