Periodic Replacement Lowers Packing Machine Breakdowns Using Maintenance Ledgers

General Background: Machine reliability is essential in modern manufacturing because unexpected breakdowns can disrupt production flow, increase downtime, and reduce operational stability. Specific Background: PT XYZ, a ceramic manufacturing company, uses an Easyline Packing Machine as a key packaging machine, but repeated failures occurred in pusher and lifting components under a corrective maintenance system. Knowledge Gap: Previous maintenance studies have focused mainly on mathematical interval calculation, while limited attention has been given to maintenance ledger quality as the basis for reliability analysis and periodic replacement decisions. Aims: This study aimed to analyze maintenance ledger data, identify critical packing machine components, calculate reliability parameters, and determine optimal periodic replacement intervals. Results: The pusher and lifting components were identified as critical components because they recorded high failure frequency and downtime contribution. Before the proposed system, pusher failure occurred 7 times with 206 minutes of downtime, while lifting failure occurred 6 times with 121 minutes of downtime. The Mean Time to Failure was 82.285 minutes for pusher and 74.600 minutes for lifting. The optimal periodic replacement interval was 51 days for pusher and 47 days for lifting. Novelty: This study positions maintenance ledger data as the decision basis for periodic replacement in packing machine maintenance. Implications: The findings support planned preventive maintenance, reduced breakdown potential, improved production stability, and more systematic machine reliability management. Highlights: Pusher and lifting were identified as the most critical components. MTTF reached 82.285 minutes for pusher and 74.600 minutes for lifting. Scheduled replacement was set at 51 days and 47 days. Keywords: Breakdown, Maintenance Ledger, Mean Time To Failure (MTTF) Periodic Replacement, Preventive Maintenance