Presentation - Pdca 8 Steps Improvement

To Improve the Preparation of
ARD samples by 100 % within 3

Months
KOMPAK – Tokek Belang
Dept.:Laboratory
2
“To Improve the ARD Sample finished by 100% in Preparation KOMPAK Implementation
KOMPAK ImplementationPProgress
rogress
Trubaindo Office
Jakarta Coal Mining
Room“Iof laboratoryDWithin
mprovement ata System From NAG test to Acid Base Accounting (ABA) Methods“
3 Months”
Nurul Fitriani Agustin Sandana Mery Marthen

Promotor Facilitator Group Leader
Sonteng Suriansyah Thomas

Secretary Member Member
Sunaryo Amirah
Member Member
KOMPAK = KKOMPAK
elOMpok Peningkatan
: KelOMpok AAktivitas
Peningkatan Kerja
ktifitasKerja = Group
= Group of working Activity Improvement
of working = SGA
activity improvement = SGA
2
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
1. KOMPAK PROFILE
2. KOMPAK Step 1 – Problem Identification and Theme Setting
3. KOMPAK Step 2 – Analyze Situation and Topic Setting
4. KOMPAK Step 3 – Analyze and Verifying Root Cause
5. KOMPAK Step 4 – Improvement Plan
6. KOMPAK Step 5 – Implementation of Improvement Plan
7. KOMPAK Step 6 – Check and Evaluate Results
8. KOMPAK Step 7 – Standardization
9. KOMPAK Step 8 – Next Improvement Theme and Result Sharing
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
Schedule of KOMPAK Activity
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Schedlue (weekly)
2012 2013
8 Step
September October November December September Remark
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
1 Problem Identification and Theme Setting
2 Analyze Situation and Topic Setting

P Mid Presentation
3 Analyze and verifying Root Cause
4 Improvement Plan
D 5 Implementation of Improvement Plan
C 6 Check and Evaluate Results
Final
7 Standardization
presentation
A
Recognizing
8 Next improvement Theme
team effort
Plan
Action
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
1. Coal & Soil

2. Sample listed in to the 9. Sample sent to 5. Sample placed in to
Sample received by
log books the Coal & AMD Lab the sample bottle
preparation division
7. Sample Crushed by
3. Weighting sample Hammer Mill
using balance
5. Sample Crushed by 6. Sample Divided to

Jaw Crusher get the representative
4. Drying process using
Drying Sheed sample
Coal Sample
Specification
Remark: CP
CR
BG
ARD Sample
WP
Spesification
ROM
ARD
EXP
Spc. ARD
PREP
GEO
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
2. KOMPAK Step 1 – Problem Identification and Theme Setting (PLAN)
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Voting of Urgency Rank
No. Problems NF AS SNT TA AMR SR SNY MM Total Rank
1 Sample delayed to be prepared 4 3 3 2 4 4 4 4 28 I
2 ARD samples contamination 2 4 4 3 3 3 3 3 25 II
3 Noise in Preparation Room 1 1 1 4 1 2 1 1 12 IV
4 Dust collector is not stabile 3 2 2 1 2 1 2 2 15 III
Remark :
NF = NURUL FITHRIANI
AS = AGUSTIN SANDANA
SNT = SONTENG
TA = THOMAS ALFA. E
AMR = AMIRAH
SD = SURIANSYAH DOAN
SNY = SUNARYO
MM = MERY MARTHEN
KOMPAK = KelOM
KOMPAK pok Peningkatan
: KelOMpok Peningkatan A
Aktivitas Kerja
= Group of working Activity
of working Improvement
activity = SGA = SGA
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
No. Problems Total Urgency (%) Cum (%)

1 Sample delayed to be prepared 28 35 35
2 ARD samples contamination 25 31.25 66.25
4 Noise in Preparation Room 15 18.75 85
3 Dust collector is not stabile 12 15 100
Conclution:
From the Pareto Graphic above, we found that the highest urgency problem is the problem of delaying
sample to be prepared.
KOMPAK = KelOM
Aktivitas Kerja
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Conclusion:
The charts Show that the sample received consist of 2 kinds of sample, those are coal and ARD sample.
KOMPAK = KelOM
Aktivitas Kerja
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Sample Sample Ratio Ratio

Period Pending
Received Finished Actual Target
Jan 2033 2033 0 1.00 1.00
Feb 1976 1781 195 0.90 1.00
Mar 2954 2228 726 0.75 1.00
Apr 1991 1871 120 0.94 1.00
Mey 2113 2128 -15 1.01 1.00
Jun 2343 2201 142 0.94 1.00
Jul 1896 1989 -93 1.05 1.00
Aug 2217 1971 246 0.89 1.00
Total/Average
17523 16202 1321 0.93 1.00
Conclution:
From the data, we found the deviation between actual sample finished with sample
received in Laboratory Preparation room.
KOMPAK = KelOM
Aktivitas Kerja
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Sample Sample
Period Pending
Received Finished
Jan 2033 2033 0
Feb 1976 1781 195
Mar 2954 2228 726
Apr 1991 1871 120
Mey 2113 2128 -15
Jun 2343 2201 142
Jul 1896 1989 -93
Aug 2217 1971 246
Total/Average 17523 16202 1321
Conclution:
From the data, we found the deviation between ratio of actual sample finished with ratio target by
93% actual sample finished from 100% Target.
KOMPAK = KelOM
Aktivitas Kerja
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
From the Graphic, we found the deviation between ratio of actual sample finished with ratio target
by 93% actual sample finished from 100% target for the period of January to August 2012.
Base on that, we agree to choose a theme:
“To Improve the Sample Finished as the sample Received in Preparation

Room of Laboratory”
The reason we choose the theme are:

1. We expect to achieve sample finished as the amount of ample received
2. To eliminate the sample pending in preparation room of laboratory.
KOMPAK = KelOM
Aktivitas Kerja
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Period Sample Received

Finished Pending
Jan 1456 1456 0
Feb 1181 1181 0
Mar 1628 1628 0
Apr 1271 1271 0
May 1528 1528 0
Jun 1601 1601 0
Jul 1389 1389 0
Aug 1371 1371 0
Total/Average 11425 11425 0
Conclution:
From the data, we didn’t find any deviation between actual sample finished with sample received, in
other words we finished the target for sample coal preparation by 100%.
KOMPAK = KelOM
Aktivitas Kerja
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Period S Received S Finished Actual Ratio Target Ratio Pending

Jan 577 577 1.00 1.00 0
Feb 795 600 0.75 1.00 195
Mar 1326 600 0.45 1.00 726
Apr 720 600 0.83 1.00 120
Mey 585 600 1.03 1.00 -15
Jun 742 600 0.81 1.00 142
Jul 507 600 1.18 1.00 -93
Aug 846 600 0.71 1.00 246
Total 6098 4777 0.85 1.00 1321
Conclution:
From the data, we found the deviation between actual ARD sample finished with sample
received. Samples are not finished 100% as the sample received.
KOMPAK = KelOM
Aktivitas Kerja
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Conclution:
From the data, we found that:
1. Coal Sample are finished as the sample received, so that all sample finished 100% as the
target,
2. The deviation show up from the achievement of preparation ARD sample that only finished
84.59 % from 100% target.
KOMPAK = KelOM
Aktivitas Kerja
improvement
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Sample finished in Preparation Room
sample
Condition amount/month Preparation Capacity
(%)
Sample finished
Realization 597 78
S Received=S
finished 762 100
Target
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
4. KOMPAK Step 3 – Analyzing & Verify Root Cause (PLAN)
Trubaindo Office
Coal Mining
rogress
Jakarta Room“Iof laboratoryDWithin
3 Months”
2 1
Samples were
Sample is in Sludge
wrong estimation of form not Finished
material needs Lag in drying process as its received
Long Processes of preparation steps
run out of the sample bottle
Sample received more The temperature of drying Less of preparation

than laboratory sheed is not stabile crew in one shift
preparation room capacity
The Schedule system

Less capacity Drying process of ARD is not effective
of preparation samples are processed in
time the same drying with coal
sample
4
3
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Data Collected
140
No (X) (Y) Remark:
120 R² = 1
1 1 36 100 X = The level of sludge sample
2 2 48 80 Y = Additional time in preparation (hours)
(Y)
3 3 60 60
4 4 72 40
20
Conclusion :
5 5 84
0 ► Coefficient correlation r2 = 1
6 6 96
7 7 108
0 5 10 ► Positive Correlation, strong relationships
(X)
8 8 120
Data Collected
No (X) (Y) Remark:
1 10 6 X = The number of sample bottle needs
2 20 6 Y = The additional time in sample preparation
3 25 12
(hours)
4 30 12
5 35 12
Conclusion :
6 40 24 ► Coefficient correlation r2 = 0.8459
8 50 24
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
4.2.3 Drying process of ARD samples are processed in the same drying instrument with coal sample
Data Collected
No (X) (Y) Remark:
1 2 4 X = Frequency of unstable temperature
2 5 8 Y = The amount of coal preparation in the same
3 7 8 drying sheed with ARD
4 8 8
5 10 12
Conclusion :
6 14 16
7 15 16
► Coefficient correlation r2 = 0.9587
4.2.4 The schedule system is not effective
Data Collected
Remark:
No (X) (Y)
X = The number of crew in one shift
1 1 10
Y =The amount of sample prepared
2 1 12
3 2 15
Conclusion :
4 2 18
► Coefficient correlation r2 = 0.7889
5 2 20
► Positive Correlation, strong relationships
6 2 20
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
Trubaindo Office
Coal Mining
rogress
3 Months”
4.3 Table of Examination Result of Dominant Causes

No Dominant Cause r r2 % Degree
1 Sample is in sludge form 1 1 27.83 100
2 Wrong estimation of material needs 0.9197 0.8459 23.54 85
Drying process of ARD samples are processed in the same

3 0.9791 0.9587 26.68 96
drying instrument with coal sample
4 The schedule system is not effective 0.8882 0.7889 21.95 79
Total 3.7871 3.5935 100 360
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
5. KOMPAK Step 4 – Improvement Plan (PLAN)
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Where
Dominant How
No. Why What When How
Causes Much
Who
To complete the drying process of all Preparation Room of

samples that aims to evaporate the water & Laboratory
moisture content in sample. Drying sample
have to be done as soon as possible with
the complete process & complete result,
Use the wider tray. Collected
because of the moisture content in sample To make a
Sample is in can oxidize the sulfur in pyrite formation, 22-Oct-12 the data whether there were
1 greater surface 100%
sludge form then will brings the low estimation of the significant differences in
of sample dried.
chemical analysis. using general & wider tray.
Not wasting time in completing the drying

process. Agustin
Preparation Crew
Preparation Room of
To maximize the drying process. ARD & coal Laboratory
samples have the difference characteristic,
Drying process formation & shape. The principle of
using the Prepare & installing the new
of ARD samples preparation of both sample are different,
instrument 27-Oct-12 drying sheed instrument that
are processed in where coal samples need only 4 hours to dry
2 special for soil would be use daily for soil 100%
& ARD samples need at least 24 hours. This
the same drying sample sample analysis
condition will make the interferences to the
instrument with drying quality process of ARD samples due Agustin
coal sample to the unstable moisture.
Sonteng
Preparation Crew
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
5. KOMPAK Step 4 – Improvement Plan (PLAN)
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Where
Dominant How
No. Why What When How
Causes Much
Who
Preparation Room of
Laboratory
To coordinate the material ordering.
To prevent possibility
Wrong To make a sure that sample If the new sample bottles cannot be
of running out of
3 estimation of bottles are available in enough 30-Oct-12 available, the another initiative is by 100%
sample bottle
material needs amount everyday. cleaning up all the sample bottles from the
samples that already analyzed.
Sonteng
Nikasius Sofyan
Preparation Room of
Laboratory To make the schedule of work.
The schedule To make the affective To arrange the preparation 04-Sept-12 To coordinate the crew about the schedule
4 system is not & efficiency of time crew to work by work schedule of duty, leaving, or day off for each crew. To 100%
Agustin
effective work communicate the schedule before approving
Sonteng & make a sure that all crew work as the
work schedule.
Preparation Crew
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
6. KOMPAK Step 5 – Implementation of Improvement Plan (DO)
Trubaindo Office
Coal Mining
rogress
3 Months”
No Idea Improvement Date/PIC Monitoring Decision
Use the wider tray.

Collected the data By using the 213.6 %
whether there were the 10-Nov-12 wider area tray, the
significant differences drying process can be
To make a
in using general & Agustin maximize.
1 greater surface of
sample dried wider tray. Sonteng
Prep. Crew Result:
Success 100%
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
Trubaindo Office
Coal Mining
rogress
3 Months”
No Idea Improvement Date/PIC Monitoring Decision
16-Nov-12 The graphic shows

Prepare & installing that all sludge sample
the new drying sheed were dried with not
using the instrument that would Agustin significant frequency
instrument be use daily for soil of unstable
2 special for soil sample analysis Nikasius temperature.
sample
Sofyan
Result:
Success 100%
To coordinate the
material ordering. The graphic shows
To make a that there is no
sure that If the new sample frequency of running
sample bottles bottles cannot be 10-Nov-12 out of sample bottle.
3 are available in available, the another
enough initiative is by Result:
amount cleaning up all the Nikasius Success 100%
everyday sample bottles from Sofyan
the samples that
already analyzed.
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Date/
No. Idea Improvement Monitoring Decision
PIC
To make the schedule of work.

The chart shows that there
To coordinate the crew about 02-Dec- is no frequency of less of
To arrange the 12 man power in one shift.
the schedule of duty, leaving,
preparation
4 or day off for each crew. To
crew to work by
communicate the schedule Result:
work schedule
before approving & make a Sonteng Success 100%
sure that all crew work as the
work schedule.
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
7. KOMPAK Step 6 – Check & Evaluate Result (CHECK)
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
No. Dominant Root Cause Before Improvement After Improvement Conclusion
By using the wider

tray, the timing of
drying process can be
1 Sample is in sludge form reduce to 213.6%, or
twice earlier than
before improvement
By using the special

Drying process of ARD drying sheed for ARD
samples are processed sample, the frequency
2 in the same drying of unstable
instrument with coal temperature can be
reduce to 75.32%
sample
By prepare the
sample bottle before
Wrong estimation of preparation the
3 running out of sample
material needs
bottle can be
eliminate 100%.
By making sure that

all the preparation
crew work as the
The schedule system is effective schedule,
4 the case of less of
not effective
man power in one
shift can be eliminate
100%.
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
8. KOMPAK Step 7 – Standardization (ACTION)
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
9. KOMPAK Step 8 – Next Imrovement Theme & Result Sharing (ACTION)
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Voting of Urgency Rank Finished

No. Problems NF AS SNT NS AMR LZ SNY MM Total Rank
1 Sample delayed to be prepared 4 3 3 2 4 4 4 4 28 I
Voting of Urgency Rank
1 ARD samples contamination 2 4 4 3 3 3 3 3 25 I
2 Noise in Preparation Room 1 1 1 4 1 2 1 1 12 III
3 Dust collector is not stabile 3 2 2 1 2 1 2 2 15 II
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
Schedlue (weekly)
2013
8 Step
Oct Nov Dec Remark
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3
Problem Identification and Theme

1
Setting
2 Analyze Situation and Topic Setting

Mid
P Presentation
3 Analyze and verifying Root Cause
4 Improvement Plan
D 5 Implementation of Improvement Plan
C 6 Check and Evaluate Results
Final
7 Standardization
presentation
A
Next improvement Theme and Recognizing
8
Management Approval team effort
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA
rogress
Trubaindo Office
Jakarta Coal Mining
3 Months”
KOMPAK = KKOMPAK
elOMpok Peningkatan
Peningkatan Kerja
of working = SGA

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To Improve the Preparation of

ARD samples by 100 % within 3

Nurul Fitriani Agustin Sandana Mery Marthen

Sonteng Suriansyah Thomas

1 Problem Identification and Theme Setting

2 Analyze Situation and Topic Setting

D 5 Implementation of Improvement Plan

C 6 Check and Evaluate Results

1. Coal & Soil

5. Sample Crushed by 6. Sample Divided to

Voting of Urgency Rank

No. Problems NF AS SNT TA AMR SR SNY MM Total Rank

1 Sample delayed to be prepared 4 3 3 2 4 4 4 4 28 I

2 ARD samples contamination 2 4 4 3 3 3 3 3 25 II

3 Noise in Preparation Room 1 1 1 4 1 2 1 1 12 IV

4 Dust collector is not stabile 3 2 2 1 2 1 2 2 15 III

No. Problems Total Urgency (%) Cum (%)

Sample Sample Ratio Ratio

“To Improve the Sample Finished as the sample Received in Preparation

The reason we choose the theme are:

Period Sample Received

Period S Received S Finished Actual Ratio Target Ratio Pending

From the data, we found that:

Sample finished in Preparation Room

Sample received more The temperature of drying Less of preparation

The Schedule system

4.2.4 The schedule system is not effective

4.3 Table of Examination Result of Dominant Causes

1 Sample is in sludge form 1 1 27.83 100

2 Wrong estimation of material needs 0.9197 0.8459 23.54 85

Drying process of ARD samples are processed in the same

4 The schedule system is not effective 0.8882 0.7889 21.95 79

Total 3.7871 3.5935 100 360

To complete the drying process of all Preparation Room of

Not wasting time in completing the drying

No Idea Improvement Date/PIC Monitoring Decision

Use the wider tray.

No Idea Improvement Date/PIC Monitoring Decision

16-Nov-12 The graphic shows

To make the schedule of work.

No. Dominant Root Cause Before Improvement After Improvement Conclusion

By using the wider

By using the special

By making sure that

Voting of Urgency Rank Finished

Problem Identification and Theme

2 Analyze Situation and Topic Setting

D 5 Implementation of Improvement Plan

C 6 Check and Evaluate Results

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