ST-03RUNNINGCriticality ASterilizer
Manufacturer
Sinar Steel Works
Model
HZ-2700
Location
Mill A · Sterilization
Commissioned
2020-11-02
Age
6 years
Operating hours
35,659 h
Utilization
88%
Availability (90 d)
97%
MTBF / MTTR
3,017 h / 7.1 h
Replacement cost
Rp 4.60 bn
Sensors
vibration, temperature, pressure, current
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
84/100
Failure probability
14%7 days
Remaining useful life
181days
Anomaly score
0.110–1
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 14% 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
Vibration RMS trend
+4.2 pp
Temperature deviation
+2.6 pp
Pressure variation
+1.7 pp
Age / operating hours
+1.5 pp
Motor current / load
+1.0 pp
Recent preventive maintenance
−2.0 pp
◀ lowers predictionraises ▶
Sensor trends & failure forecast
60-day history (daily) · dashed = model forecast
Vibration · mm/s RMS
Warning 4.5 · Alarm 7.1 mm/s RMS
No degradation trend — forecast shown only when the model detects a trajectory toward the failure threshold.
Maintenance Decision Intelligence
Weighs failure probability, criticality, downtime impact, repair vs replacement cost, spare availability and production schedule
Decision inputs
Failure probability (7 d)14%
CriticalityClass A · production-critical
Downtime impactRp 165 m / h
Planned repair costRp 138 m
Replacement costRp 4.60 bn
Spare availabilityBR-6208: 0 local · transfer from other warehouse
Production schedulePeak crop · next shutdown Sun
Option suitability
Monitor76
Failure risk low; condition monitoring sufficient
Schedule maintenance50
Fits next planned shutdown; balances risk and production
Replace component13
No single failing component identified
Replace asset10
Health 84/100 and age 6 yrs do not justify capex
Repair now2
Stops the line during peak crop — restan and emergency premium
Scenario comparison
OPTION A
Repair immediately
Stop line now, replace component using emergency transfer
Failure risk2%
Expected costRp 554 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 risk5%
Expected costRp 217 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 risk14%
Expected costRp 250 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 250 m vs Rp 250 m if left to run; residual risk 14%.
Spare parts availability
Key parts for ST-03 across the warehouse network · home store WH-01
Cross-module: Inventory AI
BR-6208 · Bearing 6208-2RS (sterilizer door drive / conveyor)
Lead time 21 d · Rp 1.9 m/pcs · 30-d demand 5
WH-01 · Mill A (home)
0 pcs · SS 2
WH-02 · Mill B
3 pcs · SS 2
SEAL-ST-900 · Sterilizer door gasket 2.7 m
Lead time 28 d · Rp 7.8 m/pcs · 30-d demand 1.1
WH-01 · Mill A (home)
5 pcs · SS 1
WH-02 · Mill B
9 pcs · SS 1
VLV-DN150 · Steam valve DN150
Lead time 30 d · Rp 16.0 m/pcs · 30-d demand 0.8
WH-01 · Mill A (home)
5 pcs · SS 1
WH-02 · Mill B
7 pcs · SS 1
Maintenance records
CMMS history, open work orders, failure events and spares
No open work orders — asset on standard PM schedule.