DG-03RUNNINGCriticality ADigester
Manufacturer
Sinar Steel Works
Model
DG-3500
Location
Mill A · Digestion
Commissioned
2008-10-08
Age
18 years
Operating hours
100,346 h
Utilization
86%
Availability (90 d)
96.2%
MTBF / MTTR
2,321 h / 9.6 h
Replacement cost
Rp 1.30 bn
Sensors
current, temperature, rpm, vibration
Region
Sumatra
Health score
Predictive maintenance
Asset Failure Prediction v3.2 · gradient-boosted survival model on IoT, SCADA and CMMS history · refreshed 06:52
Confidence79%
Health score
78/100
Failure probability
16%7 days
Remaining useful life
202days
Anomaly score
0.210–1
Likely cause
No abnormal failure mode detected
Recommendation
Continue condition monitoring; next PM as scheduled
What the model sees
Confidence79%All monitored signals are within normal bands. Failure probability 16% over 7 days; continue condition monitoring and scheduled PM.
Why this prediction — top drivers (pp of failure probability)
Baseline failure rate for class ≈ 12% · bars push probability up or down
Motor current / load
+5.0 pp
Age / operating hours
+4.5 pp
Temperature deviation
+3.1 pp
Speed deviation
+2.0 pp
Vibration RMS trend
+1.2 pp
Recent preventive maintenance
−2.0 pp
◀ lowers predictionraises ▶
Sensor trends & failure forecast
60-day history (daily) · dashed = model forecast · anomaly began 14 Sep
Motor current · % FLA
Warning 88 · Alarm 96 % FLA
No degradation trend — forecast shown only when the model detects a trajectory toward the failure threshold (forecast available for vibration & temperature).
Maintenance Decision Intelligence
Weighs failure probability, criticality, downtime impact, repair vs replacement cost, spare availability and production schedule
Decision inputs
Failure probability (7 d)16%
CriticalityClass A · production-critical
Downtime impactRp 165 m / h
Planned repair costRp 39 m
Replacement costRp 1.30 bn
Spare availabilityARM-DG-12: not in stock — procure
Production schedulePeak crop · next shutdown Sun
Option suitability
Monitor74
Failure risk low; condition monitoring sufficient
Schedule maintenance54
Fits next planned shutdown; balances risk and production
Replace asset39
Asset 18 yrs — evaluate capex replacement
Repair now2
Stops the line during peak crop — restan and emergency premium
Replace component2
No single failing component identified
Scenario comparison
OPTION A
Repair immediately
Stop line now, replace component using emergency transfer
Failure risk2%
Expected costRp 455 m
Planned downtime4 h
Lowest risk, but interrupts peak-intake processing and creates restan.
OPTION B
Repair in low-production window
Replace at next planned shutdown
Failure risk6%
Expected costRp 118 m
Planned downtime4 h
Balances failure risk against production loss at the next planned shutdown.
Recommended
OPTION C
Continue monitoring
Run to next scheduled shutdown (14 days)
Failure risk16%
Expected costRp 238 m
Planned downtime0 h
Recommended — risk is low; keep condition monitoring and standard PM.
Recommendation: Monitor
Confidence80%Continue condition monitoring; next PM as scheduled. Option C expected cost Rp 238 m vs Rp 238 m if left to run; residual risk 16%.
Spare parts availability
Key parts for DG-03 across the warehouse network · home store WH-01
Cross-module: Inventory AI
ARM-DG-12 · ARM-DG-12
Lead time 14 d · Rp 0/pcs
Not stocked — procured on demand.
GBX-OIL-320 · GBX-OIL-320
Lead time 14 d · Rp 0/pcs
Not stocked — procured on demand.
Maintenance records
CMMS history, open work orders, failure events and spares
No open work orders — asset on standard PM schedule.