FIELD

TRIP
REPORT
• Central Workshop
Mill
• Store Area

Group 2
Engineering Development Trainee Batch 9

10052265 | Alvin Ekaputra

10052266 | Imelda Elisabeth Silaban
10052281 | Yusup Bastari


CENTRAL WORKSHOP MILL

Time : June 9, 2017 (08.30 - 11.30 WIB)

Facilitators : Mr. Dasrul Amri; Mr. Donny Febrian

Central workshop mill is a department that manages maintenance equipment from mill. It
consists of reliability section (conditioning monitoring, lubrication, and hydraulic), civil
maintenance (civil and engineering, namely concrete structure and refractory bricks), and
workshops. In doing the maintenance, central workshop can do it by itself or by asking help
from the vendor. For example, to repair the multi stack pump, the workshop is helped by
the vendor. The multi stack’s pressure can be 1,000 bar and it needs a really high precision.
Besides that, it also needs special material. That’s why the maintenance of the multi stack
pump needs to be helped by the vendor. However, there are still many maintenance
activities that must be done by central workshop, namely seal changing. It can be hundreds
of seals that must be maintained.

If there is equipment’s problem in mill, the officer will send notification to central
workshop. Then, the central workshop will come to check and confirm the problem by
following the SAP, so that everything is recorded, namely the date of maintenance, the
complaint, how many times the equipment has been repaired, etc. From the recorded data,
the central workshop will find the root cause of the problem. The central workshop will not
do the maintenance in the area of mill. The broken equipment must be sent to central
workshop. After being repaired, the equipment must be brought and installed by the
mechanic who works in the area where the damaged equipment is, not by the mechanic in
central workshop.
Prev

Central workshop usually repairs the broken equipment, while area maintenance does area
preventive maintenance. If there is any broken equipment that has not met the standard
anymore, the central workshop will make a NCR (Non Conformance Report), which states
that the repaired tool is no longer up to standard. Sometimes, it can be a problem for central
workshop. The person requesting the repair does not tell all the real condition of the

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machine, he just tells things that matter to him. For example, if there is a pump that the
engine is hot, the person who asks for the repair will only convey that the engine is hot
when he doesn’t know that the pump shaft is damaged. The central workshop will make a
NCR for this equipment.

The central workshop also does equipment modification. For example, the compactor that
used to process the ground that will be the place of Acacia planting. The target performance
of central workshop is 95% from all jobs that has been received. There are workshops in
central workshop mill, they are mechanical workshop, electrical workshop, and instrument
workshop.

1. MECHANICAL WORKSHOP

Mechanical workshop is a place to maintain mechanical equipment. There are 4 areas in

mechanical workshop, they are:

Ø Fabrication Area

Fabrication in mechanical workshop which does welding job in screw press, heat
exchanger, casting iron, stainless steel, carbon steel and etc. The example job of this
division is to make a screw that used as a reclaimer. The fringe of the screw is made of
is made from a flat plate, which made of stainless steel and carbon steel. The plate was
originally a circle. Then, part of the juring of the circle is cut so that the rectangle is
generated. The calculation of the area of cut juring is done by a certain formula. Finally,
the two ends of the resulting rectangle are joined by wrapping them around the screw bar
with a certain slope. The screw can be seen in Figure 1.

Figure 1. Screw that used as a reclaimer

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Ø Maintenance Area
Maintenance in mechanical workshop purposes to repair all rotating equipment in mill,
such as gear box, pump, and motor. There are two balancing machines in maintenance
area. They are 2 tons and 4 tons. If the rotating equipment is not be balanced, it can be
broken because of its vibration. The balancing machine can be seen in Figure 2.

Figure 2. The balancing machine

The example of broken equipment that will be repaired can be seen in Figure 3.

Figure 3. The broken gear box

Gear box purposes to change the torsion (rotation). Gear box is driven by motor. The
power used is contrary to the torsion. The gear box in Figure 1 was used in wood yard
reclaimer, but it is worn out. It will be sent to Jakarta and be repaired there. The repair
can not be done in central workshop because the tools needed to repair the gear box are

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not available in central workshop and it needs a really high precision, approach 0.03 𝜇m.
The example of equipment that has been repaired in central workshop can be seen in
Figure 4.

(a) (b)
Figure 4. Repaired equipment in maintenance area : gear (a) and gear box (b)

The maintenance area will also maintain the pressurized vessel, namely heat exchanger.
In Figure 5, there is a heat exchanger that will convert the black liquor to heavy black
liquor. The work pressure is 12 bar. It has 700 tubes that must be changed. It will be
done 2 or 3 months.

Figure 5. Heat exchanger that will be repaired in maintenance area

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Besides all the things that have been mentioned before, there is also a broken reclaimer
that used in boiler to take the sands. It can be seen in Figure 6.

Figure 6. Broken reclaimer that used in boiler

Ø Machining Area

Machining in mechanical workshop does the milling, lathe, and boarding. The layout of
machining area can be seen in Figure 7, while the standard work sheet in machining area
can be seen in Figure 8.

Figure 7. The layout of machining area in central workshop

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Figure 8. Standard work sheet in machining area

The structural organization of machining area can be seen in Figure 9.

Figure 9. Structural organization in machining area

The examples of machine in machining are can be seen in Figure 10 and 11.

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Figure 10. Lathe machine

Figure 11. Milling machine

Ø Generator

There are 90 units of generator that has to be maintained. Generator division does the
preventive and corrective maintenance for generator.

2. ELECTRICAL WORKSHOP

The electrical workshop’s main job is support the production process that related to
electrical motor. Besides that, electrical workshop also ensures the availability of electrical
motor and it must ready to be used. In electrical workshop, EASA AR 100.2010 is used as
guide in working. EASA is an international standard that usually used as guide in
manufacturing. There are some processes in mechanical workshop. They can be seen in
Figure 12.

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Receiving Dismantle Rewinding Assemble Final Test

Figure 12. Processes in electrical workshop

Here are the explanations of each process.

Ø Receiving is process to check reported damage equipment and history of the equipment.
The receiving section can be seen in Figure 13.

Figure 13. The receiving section in electrical workshop

Ø Dismantle is process to identify the damaged equipment. The dismantle section can be
seen in Figure 14.

Figure 14. The dismantle section in electrical workshop

There are 2 kind of damage, the first one is electrical and the second is mechanical. If it
is electrical, we need to check the motor is burn out or not. If induction motor is burnt
out, it needs to be rewinded.

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Ø Rewinding is process to replace burn out motor become a new. This process must be
done correctly and also know the reason why the motor is burn out. The rewinding
section can be seen in Figure 15.

Figure 15. The rewinding section in electrical workshop

Ø Assemble is process to assemble the motor. This section can be seen in Figure 16.

Figure 16. The assemble section in electrical workshop

Ø Final test is checking parameters of operation such as vibration, noise, rotation, and
isolation resistance. After passing the final test, the repaired motor will be kept in
storage. The final test section can be seen in Figure 17.

Figure 17. The final test section in electrical workshop

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There is a parameter that must be noticed in storage area, that is IR (inventory).

IR = lead time x (1 year usage /12)

IR can help us to know how much equipment that we must store for urgent situation.
Every motor has different IR. All the repaired motor will be kept in storage and be
common equipment that can be used by all department in RPE and RAK. The repaired
motor will be returned to its area if the motor is a special motor that is not same with
other motor.

3. INSTRUMENT WORKSHOP

For instrument workshop, they only repair control valves.

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STORE AREA

Time : June 9, 2017 (14.00 - 16.45 WIB)

Facilitators : Mrs. Monalisa; Mr. Ferdinand H. Silitonga

Store department is one of common service unit. Their job desk is to receive goods, keep
and guard it, and issue the goods to needed area. Store department products such as raw
materials, spare parts, and safety equipments. Spareparts that are saved in the store
department can be divided into some types, they are:

1. Fast moving spareparts

2. Slow moving spareparts
3. Non moving spareparts
4. Insurance (critical) spareparts

Eighty percents of the spareparts belong to maintenance department and they are slow
moving spareparts. The twenty percents of the spareparts is consumable. Here are three
main processes of store department.

1. RECEIVING

Receiving section is divided into 2 kinds that is from local suppliers and import
suppliers. Flow of local goods is shown in Figure 18 (a), while flow of imported goods
is shown in Figure 18 (b). Goods from supplier arrive at mill and retrieved by Store
Department then its documents will be checked. After documents had been checked
GRN (Good Receive Notes) will be printed by receiving section. The goods that have
been accepted will be checked physically by workers. Next is clearance by Exim it is
about custom and tax. Then goods will be registered in system and good receiving. After
that goods will be given code in binning section. After binning is done, discrepancy
report will be written, this discrepancy report is to check the code in goods after binning
and when the goods are physically checked.

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Goods from importer arrive at Buatan port. At Buatan port, after unloading from cargo
ship, goods will go to clearance by Exim to do its custom and tax. After that goods will
be received at CFS (a place where containers are received) after that the goods will be
unstuffed from container and transferred to store.

(a) (b)
Figure 18. Flow of local goods (a) and imported goods (b)

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The receiving section can be seen in Figure 19.

Figure 19. The receiving section

2. INVENTORY

Inventory is when store department keep goods of customers that needed and store
department doesn’t have it spare (ready stock). In this case store department is a
hand that help customer to get goods that customer needed. The process flow
diagram of inventory process can be seen in Figure 20.

Figure 20. Process flow diagram of inventory process

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It process is customer need to submit a reorder at reorder system. Then, they need to
make a purchase requisition to store department. If there is no stock in store
department in goods that needed by customer, store department will make a pre
order to buy the needed goods by customer.

There are 3 kinds of inventory types in store department, and they are:
• Stock
Stock is items that usually or regularly used by mill. Stock item for
examples are safety equipment, electrical motors, instruments, etc.
• Non stock
Non stock is item that irregularly used by mill (customer) like special kinds
of electric motor or instruments.
• Direct purchase
Direct purchase is item that directly purchased from vendors because it
doesn’t have any spare that stored in store department. Spare part that rarely
changed is one of the example.

Here are some inventory area which belongs to the store department.

1. Mill store
Mill store is used to store spareparts from small to medium size. The mill store
can be seen in Figure 21.

Figure 21. The store area in mill

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The procedures for the preparation of goods in the store mill can be seen in
Figure 22.

Figure 22. The procedures for the preparation of goods in the store mill

2. Gate 1 and 3

Gate 1 and 3 is also used to store spareparts from small to medium size. This
storage is used when the mill store can not hold the goods anymore. The storage
area in gate 1 can be seen in Figure 23 and 24.

Figure 23. The storage area in gate 1 door 1

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Figure 24. The storage area in gate 1 door 2

3. Panel 6
Panel 6 is used to store big size spareparts and chemicals. The storage area in
panel 6 can be seen in Figure 25, while the procedures for the preparation of
goods in panel 6 can be seen in Figure 26.

(a)

(b)

Figure 25. The storage area in panel 6 : out (a) and in (b)

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Figure 26. Procedures for the preparation of goods in panel 6

Besides the storage function, the store area also does maintenance for the goods
that are kept in store area. It can be seen in Figure 27.

Figure 27. Maintenance activity in panel 6

In panel 6, there is no shift in work, so when customers want to take their order in
the night after 5 pm, they must go to the central storage and ask the officer in there
to help taking their order in panel 6.

3. ISSUING

Issuing is a process to give the requested goods/spare parts of customers. User or

customer need come to store department when they need to claim spare parts or
goods. The issuing section can be seen in Figure 28.

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Figure 28. The issuing section

The process flow diagram of issuing process can be seen in Figure 29.

Figure 29. Process flow diagram of issuing process

First, user come to store department. They need to bring along reservation number
and they must input SAP number of the goods they want claimed to system. Next,

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their reservation number will be checked by system. If the number that user brought
match with number in system, it will go to next step. After that, Good Issue and
Picking Slip will be printed. Then, items/goods will be taken from bin location
where it stored in ware house of store department.

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