Company Profile

PT Indocement Tunggal Prakarsa Tbk. has three factory complexes, which in total include 12
factories. The Citeureup factory complex in Bogor, West Java, which operates 9 factories, is
one of the largest cement plant complexes in the world. Two other factory complexes are
located in Palimanan, Cirebon, West Java and in Tarjun, Kotabaru, South Kalimantan, with
one factory. Total installed production capacity 25.5 million tons.

Cement

Capacities
Location Factory
(million ton)
Citeureup, Bogor, Jawa Barat 9 11,9 million
Palimanan, Cirebon, Jawa Barat 2 4,1 million
Tarjun, Kotabaru, Kalimantan
1 2,6 million
Selatan
Total 12 18,6 million

Citeureup Plants

Cirebon Plants

QCC Profile
QCC Quantum was formed on July 14, 2009 in the organizational structure including the
Mechanical Department, Operation Plant Division of PT. Indocement Tunggal Prakarsa, Tbk.
Tarjun Village – Kotabaru, South Kalimantan.
Nama Gugus GKM Quantum Jumlah Pertemuan 54 Kali
Ketua Bayu Prianto,ST. % Kehadiran 100%
Sekretaris Hasan Bisri Lama Pertemuan 2 Jam
Anggota Suparto Waktu Pertemuan 13:00 - 15:00
Dibentuk pada 14 Juli 2009 Tema ke 9 (Sembilan )
Fasilitator Bilter Sinaga Usia tertua 45
TQM Project Suryana,SE,MM. Usia Termuda 27
Pendidikan SLTA – S2

ORGANIZATION CHART OF QCC QUANTUM

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 (TQM Project)

Suryana

(Facilitator)

Bilter Sinaga

Leader Secretary Member

Bayu Hasan Basri Rommy S

Prianto

OPERATION PLANT DIVISION ORGANIZATION CHART

Operation Plant
DIVISION

Production Quality Control Mining Electrical Mechanical

DEPARTMENT DEPARTMENT DEPARTMENT DEPARTMENT DEPARTMENT

QCC
QUANTU
M

PLAN SCHEDULE & ACTIVITY REALIZATION

PLAN ( X ) & REALIZATION ( = )
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 Raw Mill Production Process Flow:

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Brief explanation of production process in Raw mill :
Main raw materials that used in producing cement are Limestone, Sand stone, Clay, Iron ore
and gypsum. Limestone, clay dan sandstone in mining by drilling and blasting process and
then brought to milling machine that located not far from mining. Materials that have been
milled then sent through Belt Conveyor to temporary storage that called silo. Next the
materials is lowered to belt conveyor for transferred via Overline Belt Conveyor (OBC).
Limestone, clay, sand stone, laterite are sent from quarry using Overline Belt Conveyor
(OBC) along ±26 kilometers to material storage for each type of raw material.
In storage material there is a reclaimer (material grinder) to put on the belt conveyor then
sent to dosing bin with proportional and then material from each chute bin goes down to
weight feeder except raw mix through apron feeder then brought to Raw mill via belt
conveyor to milling which the results is Raw Meal that stored and homogenization in blending
silo. Next the raw meal feed to Suspension Preheater for pre-heating process. After being
heated next in burning kiln for process to be clinker.

I. THEME SELECTION
Period : Week I – IV of February 2021

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1.1. Background
In January – December 2020 sub Key Performance Measurement ( KPM ) Mechanical
Department has red worth parameter every month namely Down Time Index. Down Time
Index is one of important indicator because Mechanical Department is a department that has
main equipments from cement production proses. This down time was a red because there
are equipment’s disturbances that result in Raw Mill stop (break down). Mechanical
department head asks in 2021 will have a change to a better way in decrease of downtime
index. How ever in Januari 2021 the Down Time Index still face a problem with red symbol
that indicate there is no significant change from mechanical department performance. So
based on that, Mechanical Department Head follow up the evaluation results by instructing to
Section Head in order to solve the problems immediately through Quality Control Circle
(QCC) by involve QSMR and facilitator representatives then formed the QCC members that
will follow up the instruction from leader to solve that problems.
Here is the KPM Production Department Data in January 2021:
Data Source : KPM Mechanical Department
Data Period : Januari 2021
` Data Collector : Hasan Bisri
Purpose : to find out actual red sub KPM
Unit : PQ.Score

Summary:
From data and diagram about, it is known that in Januari 2021 there is parameter in KPM
namely down time index that face poor performance as 50 so the performance is red.
In January 2021 one of indicator from KPM namely down time index that face poor
performance due to high downtime mechanical, This will results Mean Time Between Failure
(MTBF) index is low, with the following data:

Data Source : Mechanical Department Monthly Report

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 Data Period : January 2021
Data Collector : Hasan Bisri
Purpose : to find out Mechanical Department MTBF Index
Unit : Index

Mean Time Between Failure (MTBF)

Area
Standard Index Actual Index
Raw Mill 35 13,615
Finish Mill 85 88,5
Kiln 90 94,4

MTBF - January - 2021

100 94.4
88.5 90
90 85
80
70
60
50
40 35
30
20 13.615
10
0
Raw Mill Finish Mill Kiln

Standard Actual

Summary:
Based on data and graphic above, it is known that MTBF in January 2021 where is consist of
3 production process area that one of them has index value below standard that is very far
from expectation, as known that the lower of MTBF the higher department down time, due to
equipment failure on production process. This will result KPM mechanical department will be
red, so the Mechanical Department Head instructing to facilitator to solve down time
problems immediately through Quality Control Circle.
1.2. Determining Theme
By following up the instruction from Department Head, QCC QUANTUM doing analyze to
Down time problem. The QCC analysis results that down time problems is high due to
equipment failure on production process. Next is QCC doing problems inventarization based
on location by classifying the data according to how much the disturbances (frequency), how
long the disturbances (duration), lost product and loss value (IDR).

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1.2.1. Down Time Frequency Data based on work area

Data Source : Daily shut down report

Data Period : January 2021
Data Collector : Hasan Bisri
Purpose : To find out the down time frequency
Unit : Times

NO DISTURBANCE FREQUENCY ACCUMULATIVE % %ACCUMULATIVE

SOURCES
1 Raw Mill 12 12 29.27 29.27
2 Finish Mill 1 9 21 21.95 51.22
3 Finish Mill 2 9 30 21.95 73.17
4 Coal Mill 6 36 14.63 87.80
5 Kiln 5 41 12.20 100.00
TOTAL 41 - 100 -

1.2.2. Down Time Duration Data based on work area

Data Source : Daily shut down report

Data Period : January 2021

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 Data Collector : Hasan Bisri
Purpose : To find out the down time duration
Unit : Hours

NO DISTURBANCE DURATION ACCUMULATIVE % %

SOURCES ACCUMULATIVE
1 Raw Mill 342.03 342.03 24.95 24.95
2 Finish Mill 1 262.41 604.44 19.15 44.10
3 Coal Mill 262.19 866.63 19.13 63.23
4 Kiln 251.97 1,118.60 18.39 81.62
5 Finish Mill 2 251.95 1,370.55 18.38 100.00
TOTAL 1,370.55 - 100.00 -

1.2.3. Lost Product Data due to Downtime based on work area

Data Source : Daily shut down report

Data Period : January 2021
Data Collector : Hasan Bisri
Purpose : To find out raw mill lost product value

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 Unit : Ton

NO DISTURBANCE Lost Product ACCUMULATIVE % %

SOURCES ACCUMULATIVE
1 Raw Mill 168,002.54 168,002.54 46.91 46.91
2 Coal Mill 69,388.87 237,391.41 19.37 66.28
3 Kiln 66,684.13 304,075.54 18.62 84.90
4 Finish Mill 2 42,674.46 346,750.00 11.92 96.82
5 Finish Mill 1 11,389.32 358,139.32 3.180 100.00
TOTAL 358,139.32 - 100.00 -

1.2.4. Lost Product’s loss value Data

Data Source : Daily shut down report

Data Period : January 2021
Data Collector : Hasan Bisri
Purpose : To find out lost product’s loss value

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 Unit : Rupiah

NO DISTURBANCE LOSS VALUE ACCUMULATIVE % %

SOURCES ACCUMULATIVE
1 Raw Mill Rp. 77,281,168,699.00 Rp. 46.91 46.91
77,281,168,699.00
2 Coal Mill Rp. 31,918,879,150.00 Rp. 19.37 66.28
109,200,047,849.00
3 Kiln Rp. 30,674,701,474.00 Rp. 18.62 84.90
139,874,749,323.00
4 Finish Mill 2 Rp. 19,630,250,678.00 Rp. 11.92 96.82
159,505,000,001.00
5 Finish Mill 1 Rp. 5,239,088,542.00 Rp. 3.18 100.00
164,744,088,543.00
TOTAL Rp. 164,744,088,543.00 - 100 -

Pareto Analysis:

1. From data sheet and pareto diagram on down time frequency based on work area
above, it seems that raw mill area face the most down time as much as 12 times or
29.27 % for a month.

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 2. From data sheet and pareto diagram on down time duration based on work area
above, it seems that raw mill area face the longest down time as much as 342.03
hours or 24.95% for a month.
3. From data sheet and pareto diagram on raw mill lost product potential above, it seems
that down time raw mill has the most impact to raw mill production lost as much as
168,002.54 Ton or 46.91% for a month.
4. From data sheet and pareto diagram on lost product’s loss value above, it seems that
down time raw mill has the most impact to cement production income loss as much as
Rp.77.281.168.699,- or 46.91% for a month.

So that Raw Mill down time is priority issue, and QCC QUANTUM agreed to set the theme:

“Reducing Raw Mill Down Time in Plant 12 Tarjun”

2.2. Determining Title.

2.1.1. Raw mill area down time Data based on how much the disturbance
(Frequency).

Data Source : Daily shut down report

Data Period : January 2021
Data Collector : Hasan Bisri
Purpose : To find out raw mill down time frequency
Unit : Times

NO DISTURBANCE FREQUENCY ACCUMULATIVE % %

SOURCES ACCUMULATIVE
1 Mechanical 8 8 66.68 66.68
Equipment
2 Material Shortage 1 9 8.33 75.01
3 Process 1 10 8.33 83.34
4 Consequtive Down 1 11 8.33 91.67
5 Electrical 1 12 8.33 100
Equipment
TOTAL 12 - 100 -

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 2.1.2. Raw mill area down time Data based on how long the disturbance (duration)

Data Source : Daily shut down report

Data Period : January 2021
Data Collector : Hasan Bisri
Purpose : To find out raw mill downtime duration
Unit : Hours

NO DISTURBANCE DURATION ACCUMULATIVE % %

SOURCES ACCUMULATIVE
1 Mechanical 310.50 310.50 90.78 90.78
Equipment
2 Material Shortage 11.50 322.00 3.36 94.14
3 Process 11.13 333.13 3.25 97.39
4 Consequtive Down 06.54 339.67 1.92 99.31
5 Electrical Equipment 02.36 342.03 0.69 100.00
TOTAL 342.03 - 100.00 -

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 2.1.3. Lost Product Cement Data

Data Source : Daily shut down report

Data Period : January 2021
Data Collector : Hasan Bisri
Purpose : To find out lost product cement value
Unit : Ton

NO DISTURBANCE DURATION ACCUMULATIVE % %ACCUMULATIVE

SOURCES
1 Mechanical 152,515.24 152,515.24 90.78 90.78
Equipment
2 Material Shortage 5,648.71 158,163.95 3.36 94.14
3 Process 5,466.97 163,630.92 3.25 97.39
4 Consequtive Down 3,212.40 166,843.32 1.91 99.3
5 Electrical 1,159.21 168,002.54 0.70 100
Equipment
TOTAL 168,002.54 - 100 -

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 2.1.4. Lost Product’s loss value data

Data Source : Daily shut down report

Data Period : January 2021
Data Collector : Hasan Bisri
Purpose : To find out lost product’s loss value
Unit : Rupiah

NO DISTURBAN LOSS VALUE ACCUMULATIVE % %

CE ACCUMULAT
SOURCES IVE
1 Mech. Equip. Rp. 70,157,012.195.00 Rp. 70,157,012,195.00 90.78 90.78
2 Mat. Short. Rp. 2,598,407,859.00 Rp. 72,755,420,054.00 3.36 94.14
3 Process Rp. 2,514,806,911.00 Rp. 75,270,226,965.00 3.25 97.39
4 Consec. Rp. 1,477,703,252.00 Rp. 76,747,930,217.00 1.91 99.30
Down
5 Elect. Equip. Rp. 533,238,482.00 Rp. 77,281,168,699.00 0.70 100.00
TOTAL Rp. 77,281,168,699.00 - 100 -

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 Pareto Analysis:

1. From data sheet and pareto diagram on down time frequency above, it seems that
Mechanical Equipment is a disturbance source on raw mill with the most frequency as much
as 8 time for a month.
2. From data sheet and pareto diagram on downtime duration above, it seems that Mechanical
Equipment is a disturbance type on raw mill with the most duration as much as 310,50 hours
for a month.
3. From data sheet and pareto diagram on raw mill lost product, it seems that Mechanical
Equipment is a disturbance type that can affect to raw mill prodcution loss as much as
152,515,24 Ton or 90,78% for a month.
4. From data sheet and pareto diagram on lost product’s loss value, it seems that Mechanical
Equipment is a disturbance type that can affect to cement production income lost as much as
So that Mechanical Equipment
Rp.70.157.012.195,- or 90,78% are
for apriority
month.issues, and QCC QUANTUM agreed to
set the title:

“Eliminating Mechanical Equipment Downtime On

Raw Mill Production Process In Plant 12 Tarjun For
8 Months”
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 2.2. Initial Goal
INITIAL GOAL

310.5

350

300 100%
250

200

150 0
100

50

0
Before Repair Initial Goal

The Reason for Setting Initial Goal:

1. Target from Mechanical Department is to prevent raw mill downtime due to mechanical
equipment failure.
2. Experience and optimism from QCC members
3. There are full supports from management
2.3. Repair Benefit:
Tangible:

1. Raw mill downtime due to mechanical equipment failure can removed

2. Reducing cement reject, ripped belt and purchase of gearbox
3. Cost saving that can obtain for a year are following:
No Loss Type Loss Value
1 Lost Cost Production Benefit Rp. 70,157,012.195.00
2 Replace Planetary Gear Apron Rp 19,600,000,000.00
Feeder
3 Replace Scrapper Rp. 10,000,000.00
4 Resplicing Rp. 3,080,000.00
5 Replace Chain Rp. 40,000,000.00
6 Loss HD Oil Rp. 225,000.00
7 Cement Reject Rp. 2,300,000.00
Cost Saving Total Rp. 89,812,617,195.00

Intangible:
1. Reducing employee work accident risk
2. Increase the employee work motivation
3. Increase good relations between management and subordinate

2.4. QCC Performance

QCC Performance data sheet and work area quality before doing repair

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 Summary:
From the data sheet and radar chart above, it
shows that the QCC performance average
score is 2.30 while the average score for the
quality of the work site is 2.67. From the
data sheet and Rinda window above, it
shows that the QCC performance and the
quality of the work site are in zone C,
QCC QUANTUM – MECHANICAL DEPARTMENT P. 12 TARJUN
meaning that KOTABARU-
the quality of QCC and the
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work site is at an average stage, it is hoped
that after Manufacture improvements it can
increase to zone B, which means it is in a
good stage
Knowledged By: Approved By: Submitted By:

Retnawan W. Herwan S Suryana. Bilter Sinaga Bayu Prianto

General Manager Mechanical TQM Staff Facilitator Leader
Dept.Head

II. ANALYSIS OF CAUSES

Period: Week I March – Week IV May 2021

3.1. Members Brainstorming

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3.2. Causes Stratification

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3.3. Ishikawa

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2.4. Nominal Group Technique.

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 Summary:
Based on Nominal Group Technique Voting results, The dominant suspected
causes on ranking 1–12, among:
1. 1 – 4 391 CV Shaft Tension moved.
2. 311 RE 1 Harrow Teeth is not strong enough. NGT = ½ N
3. Shaft output stick to apron. = ½. 20
4. 341 SX2 Sprocket spilled by Material. = 10
5. 361 HD1&2 Pipe Wood Clamp is not strong enough.
6. 361 RM1 Damring is not high enough.
7. 311 RE1 Scrapper Liner is easy to bent.
8. Range between 361 ECS Bin chute with 361 WF1 Belt is too close.
9. The Patroller is not Mechanic.
10. There is no Bolt tightness frequency monitoring.

Ten dominant suspected cause factors above then we’ll evaluate by correlation analysis
on the next steps.
INFLUENCING FACTORS
Period: 1st Week of April s/d 4th Weeks of May 2021
3.1. Hypothesis test
3.1.1.Cause of range between ECS Bin Chute with 361 WF1 Belt is too close.
Testing Purpose : To find out the relationship among range between chute to belt
with squeezed Raw material
X Indicator : Range between chute to belt (Cm)
Y Indicator : Equipment failure duration (hours)
Testing Date : 03 - 15 Apr 2021

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Method : Observation & record
Observation Object : Material that passed 361ECS Bin chute
Data Collector : Suparto

N = 11
R = -0.770
R2 = 0.593
59.30%

Summary: Cause of range between ECS Bin Chute

with 361 WF1 Belt is too close.
From data and scatter diagram, it is known that there is
strong negative correlation with r value = -0.770
and r = 0.593 with correlation strength as 59.3% , it
2

means that the range between 361 ECS chute to 361

WF1 belt is getting wider, then it will decrease the
equipment’s failure or in other words the longer the
tools is operates. So this cause will be followed up for
doing repairs in the next step.

3.1.2. Cause : 311 RE1 Scrapper Liner is easy to bent.

Testing Purpose : to find out the relationship between how much scraper liner
claw loose
With how long the equipment’s disturbance
X Indicator : Total of scraper liner claw loose (Pcs)
Y Indicator : Equipment disturbance duration (hours)
Testing Date : 03 - 19 Apr 2021
Method : Observation & record
Observation Object : 311 RE1 Scrapper Liner
Data Collector : Hasan Bisri

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 N = 15
R = 0.889
R2 = 0.790
79.03%

Summary:

From data and scatter diagram, it’s known that there is strong positive correlation between
how much scrapper liner claw loose with how long the equipment disturbance, that the more
scrapper liner claw loose, so the longer equipment’s failure that resulting stop on raw mill
production process with r value = 0.889 dan r 2 = 0.790 with correlation strength as much as
79.03% . then this cause will be follow up for repair in the next step.

3.1.3. Penyebab Horrow Teeth 311 RE 1 Tidak Kuat

3.1.3. Cause : 311 RE1 Harrow Teeth is not strong enough.
Testing Purpose : To find out the relationship between how much 311RE 1
Harrow Teeth
Loose with how long the equipment’s disturbance
X Indicator : How much the Harrow Teeth loose (Pcs)
Y Indicator : How long the equipment’s disturbance (hours)
Testing Date : 01 - 15 Apr 2021
Method : Observation & Record
Observation Object : 311 RE1 Harrow Teeth
Data Collector : Bayu

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 N = 15
r = 0.975 r2 = 0.952%

Summary:

From data and scatter diagram above, it’s known that there is strong positive correlation between
how much the harrow teeth loose with how long the equipment’s disturbance, the more harrow
teeth loose, the longer the equipment’s disturbance that resulting stop on raw mill production
process with r value = 0.975 and r2 = 0.952 with correlation strength as much as 95.17% . then this
cause will be follow up for repair in the next step.
3.1.4. Cause of 391 CV 1 – 4 tension shaft moved.
Testing Purpose : To find out the relationship between bearing shaft loose
frequency
With how long the equipment’s disturbance
X Indicator : Bearing shaft loose frequency (times)
Y Indicator : Equipment disturbance duration (hours)
Testing Date : 10 - 24 Apr 2021
Method : Observation & Record
Observation Object : Bearing Shaft
Data Collector : Bayu

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 N = 15

Summary:

From data and scatter diagram above, it’s known that there is a strong positive correlation between
bearing loose frequency with equipment disturbance duration that the more often bearing shaft broken,
the more longer the equipment disturbance that resulting stop on raw mill production process, with r
value = 0.988 dan r2 = 0.976 with correlation strength as much as 97.6 % . then this cause will be
follow up for repair in the next step.
3.1.5. Cause of 361RM1 Damring is not high enough.
Testing Purpose : To find out the relationship between material spills frequency
with
How long the equipment disturbance
X Indicator : Material spills frequency (times)
Y Indicator : Equipment disturbance duration (hours)
Testing Date : 01 - 15 May 2021
Method : Observation & Record
Observation Object : Meal Material
Data Collector : Hasan Bisri

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 Summary:

From data and scatter diagram above, it’s known that there is a strong positive correlation between
material spills frequency with equipment disturbance duration, that the more material spills, the
longer the equipment disturbance that resulting stop on raw mill production process with r value =
0.960 and r2 = 0.922 with correlation strength as much as 92.16% . then this cause will be follow up
for repair in the next step.

3.1.6. Cause of 341 SX2 Sprocket spilled by Material.

Testing Purpose : To find out the relationship between Spilage Jumping frequency
with
How long the equipment disturbance
X Indicator : Spilage Jumping frequency (times)
Y Indicator : Equipment disturbance duration (hours)
Testing Date : 01 - 10 May 2021
Method : Observation & Record
Observation Object : Spilage
Data Collector : Suparto

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 Summary:

From data and scatter diagram above, it is known that there is a strong positive correlation between
spilage jumping frequency with how long the equipment disturbance duration, which is the more often
spilage jumping, the longer the equipment disturbance that resulting stop on raw mill production
process with r value = 0.948 and r 2 = 0.898 with correlation strength as much as 89.80%. then this
cause will be follow up for repair in the next step.
3.1.7. 361 HD 1 & 2 Wood Pipe Clamp is not strong enough.
Testing Purpose : To find out the relationship between damaged wood clamp
frequency
With how long the equiment disturbance
X Indicator : Damaged Wood Clamp frequency (times)
Y Indicator : Equipment disturbance duration (hours)
Testing Date : 01 - 30 May 2021
Method : Observation & Record
Observation Object : Wood Clamp
Data Collector : Suparto

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 Summary:

From data and scatter diagram above, it is known that there is a strong positive correlation
between damaged wood clamp frequency with how long the equipment disturbance that the
more often wood clamp damaged, the longer the equipment disturbance that resulting stop on
raw mill production process with r value = 0.943 and r 2 = 0.889 with correlation strength as
much as 88.92 %. then this cause will be follow up for repair in the next step.
3.1.8. Cause of Shaft Output Stick to Apron Feeder .
Testing Purpose : To find out the relationship between installation & remove
duration
With how long the equipment disturbance
X Indicator : Planetary Gear installation & remove duration (hours)
Y Indicator : Equipment disturbance duration (hours)
Testing Date : 15 - 24 May 2021
Method : Observation & Record
Observation Object : Spilage
Data Collector : Bayu

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 Summary:

Based on data and diagram above, it is known that there is a strrong positive correlation
between planetary gear installation & remove duration to equipment disturbance on raw mill.
The longer installation & remove process of planetary gear, The longer the equipment
duration that resulting stop on raw mill production process with r value = 0.952 and r2 = 0.906
with correlation strength as much as 90.63 % . then this cause will be follow up for repair in
the next step.
3.1.9. Cause of Patroller is not Mechanic.
Testing Purpose : To find out the relationship between total of fastened bolts with
Total of broken bolts
X Indicator : Total of fastened bolts (Pcs)
Y Indicator : Total of broken bolts (Pcs)
Testing Date : 15 - 24 May 2021
Method : Observation & Record
Observation Object : Scrapper Bolt
Data Collector : Hasan Bisri

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 Summary:

From data and scatter diagram above, it is known that there is a strong positive correlation between
fastened bolts with broken bolts. correlation said that the more bolts is tight, the more bolts is
broken so resulting stop on equipment and production process, with r value = 0.954 and r2 = 0.910
with correlation strength as much as 91.01%. then this cause will be follow up for repair in the next
step.

3.1.10. Cause of There is no bolt tightness frequency monitoring.

Testing Purpose : To find out the relationship between tightening bolts frequency
With broken bolts frequency
X Indicator : Fastened bolts frequency (Pcs)
Y Indicator : Bolts age duration (hours)
Testing Date : 15 - 24 May 2021
Method : Observation & Record
Observation Object : Scrapper bolt
Data Collector : Hasan Bisri

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31
 Summary:

From scatter diagram data above, it is known that there is strong negative correlation between
the frequency with which the bolts are tightened with bolt age duration that The more often the
bolt is tightened, the faster the bolt will break that can result the scrapper fell and the
production process stopped, with correlation strength as much as 63.20 5 supported by r value
= - 0.795 and r2 value = 0.632, then this cause will be follow up for repair in the next step.

3.2. Pie Chart of Dominant Cause Composition.

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 Based on data sheet and pie chart above,
that ten suspected factor as the cause are
dominant factors. For the next ten dominant
factors, we will find solutions and
manufacture improvements in the next step.
The ten dominant causes are as follows::

1. 391 CV1 – 4 Tension Shaft moved.

2. 311 RE1 Harrow Teeth is not strong enough.
3. 361 RM1 Damring is not high enough.
4. Patroller is not Mechanic.
5. Output Shaft stick on Apron Feeder.
6. 341 SX2 Sprocket spilled by material.
7. 361 HD1 & 2 Wood Pipe Clamp is not strong enough.
8. 311 RE1 Liner Scrapper is easy to bent.
9. There is no bolt tigthness frequency monitoring.
10. Range between Chute ECS Bin to Belt 361 WF1 is too close.
3.3. Solution Selection.

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 III. SOLUTION FORMULATION & IMPLEMENTATION
Periode : Minggu I s/d minggu IV Juni 2021

4.1. Manufacture Repair Plan.

Sequence Number of Dominant 1

Cause
Dominant Cause 391 CV 1 – 4 Tension Shaft moved
Why ( Why 391 CV 1 – 4 tension So that there is a distance between the scrapper and the
shaft moved must be repaired ) casing
What ( What is the form of repair?) Manufacture tension shaft stopper
Where (Where the repair be done?)
Under 361 EP 1
When (When the repair be done?)
2 - 10 Jun 2021
Who (Who is in charge?) Hasan Bisri
How (How the steps?) Steps of activities:

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How Much (How much the
success to be achieved?)
Sequence Number of Dominant Cause
Dominant Cause
Why (Why 311 RE1 harrow teeth that not strong must be
repaired?)
What ( What is the form of repair ?)
Where ( Where the repair be done ?)
When ( When the repair be done ?)
Who (Who is in charge?)
How (How the steps?)
How Much ( How much the % success to be achieved ?)
Sequence Number
Dominant Cause
Dominant Cause
Why (Why 361 RM1 Damring that
not high enough must be
repaired?)
What (What is the form of repair?)
Where (Where the repair be
done?)
When (When the repair be done?)
Who (Who is in charge?)
How (How the steps?)
How Much (How much the %
success to be achieved?)
QCC QUANTUM – MECHANICAL DEPARTMENT P. 12 TARJUN KOTABARU-
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1. Prepare the tools.
2. Prepare the materials.
3. Cut the roundbar with 100 mm diamater to 25
mm as much as 8 pcs.
4. Hole the 30mm roundbar .
5. Hole the 30mm tension shaft.
6. Do a Tapper for the bolt .
7. Install the Stopper.
8. Repair results monitoring
% 100%
2
311 RE 1 Harrow Teeth is not strong en
So that the harrow teeth are stuck in the r
Manufacture the brace / support
311 RE1
11 - 19 Jun 2021
Suparto
1. Plate 4 mm thick in the shape o
2. Weld the plate beside the harro
3. Repair results monitoring .
100%
of 3
361 RM1 Damring is not high enough
So that the material does not spill
Increase the damring height
Above 361 RM1 table
19 – 30 Jun 2021
Bayu Prianto
Steps of activities:
1. Prepare equipment and materials (welding machine,
cable roll, hand grinder, welding wire, angle iron and iron
plate)
2. Lock out the equipment
3. Prepare the materials
4 Cut the plate bar sized 30 X 30 mm 600mm length
4. Plat on +/- R2500 rol.
5. Weld the plate bar on the table.
6. Repair results monitoring.
100%
35
 Sequence Number of 4
Dominant Cause
Dominant Cause Patroller is not Mechanic
Why (Why patroller is not So that the patroller knows the calculation of bolt
mechanic must be repaired?) tightness
What (What is the form of repair?) Socialization of bolt tightness calculation to patroller
Where (Where the repair be Standby patrol room
done?)
When (When the repair be done?)
2 - 30 Jun 2021
Who (Who is in charge?) Suparto
How (How the steps?) Steps of activities:
1. Prepare material for socialization of bolt
tightness.
2. Create a socialization invitation.
3. Do Socialization.
4. Socialization result monitoring
How Much (How much the % 100%
success to be achieved?)

Sequence Number of 5
Dominant Cause
Dominant Cause Shaft Output stick on Apron Feeder
Why (Why shaft Output stick on So that the planetary gear is not cut
apron feeder must be repaired?)
What (What is the form of repair?) Manufacture planetary gear system coupling

Where (Where the repair be 211AF1

done?)
When (When the repair be done?) 03 - 11 Jul 2021

Who (Who is in charge?) Suparto

How (How the steps?)
Step Of Activities :
 Determine the modified dimensions of the
planetary gear output shaft
 Manufacture a modified image of the
planetary gear output shaft.
 Lathes, cutting machines (saws), drilling
machines, milling machines, M24 taps and
their equipment, drills 30 and 21 mm
 Hoist and lifting equipment
 Equipment of each machine

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How Much (How much the %
success to be achieved?)
Sequence Number of 6
Dominant Cause
Dominant Cause
Why (Why the 341 SX2 sprocket
that spilled by material must be
repaired?)
What (What is the form of repair?)
Where (Where the repair be
done?)
When (When the repair be done?)
Who (Who is in charge?)
How (How the steps?)
How Much (How much the %
success to be achieved?)
QCC QUANTUM – MECHANICAL DEPARTMENT P. 12 TARJUN KOTABARU-
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 Welding transformer and its equipment
 Blender and equipment
 MIS :
 50 X 1200 X 2400 plate
 50 Kg RD 460 welding wire 4 mm
 20 pcs M30 X 115 bolts
 1 pc M24 X 30 Planting bolt
 20 pcs M30 Washer spring
 Cut the ex shaft fan 361FN4 material
according to the design size
 Cut the 50mm plate according to the design
size
 Lathe ex shaft fan material and 50mm plate
100 %
341 SX2 Sprocket spilled by material
To Keep Scrapper Load Low
Manufacture a Cannopy
341 SX2
10 - 18 Jul 2021
Hasan Bisri
Steps of Activities:
1. Prepare Tools.
2. Prepare the materials.
3. Lock Out process.
4. 5 mm plate 4 rectangular 800X600mm sized.
5. Manufacture support cannopy from iron plate
size 1.5 inc.
6. Do the welding.
100 %
37
 Sequence Number of 7
Dominant Cause
Dominant Cause HD Wood Pipe Clamp is not strong enough
Why (Why HD Wood Pipe Clamp So that HD doesn't vibrate
that not strong enough must be
repaired? )
What (What is the form of repair?) Manufacture a clamp from cannal iron.

Where (Where the repair be done?) 361HD1 & 2.

When (When the repair be done?) 19 - 27 Jul 2021.

Who (Who is in charge?) Bayu Prianto

How (How the steps?) Steps of Activities:
1. Prepare the tool.
2. Prepare the material.
3. PTW process.
4. Cut iron cannal size 200 X 700 mm.
5. Manufacture 6 holes for M20 size bolts.
6. Installation process.

How Much (How much the % 100%

success to be achieved?)

Sequence Number
Dominant Cause
Dominant Cause
Why (Why 311RE1 linner
scrapper that easy to bent must So that the Roller guide does not fall.
be repaired?)
What (What is the form of repair?)
Where (Where the repair be done?)
When (When the repair be done?)
Who (Who is in charge?)
How (How the steps?)
of 8
311 RE1 Liner Scrapper is easy to bent
Manufacture linner scrapper support
311 RE1
1 - 9 Aug 2021
Suparto
Steps of Activities:
1. Prepare equipment and materials (welding
machine, cable)
roll, hand grinder, welding wire, elbow iron
and iron plate etc)
2. Equipment Lock out ( PTW )
3. Conveyor spilage floor cleaning
4. Position the scrapper on the tail
5. Cut plate 80 mm x 300 x = 2 pcs
6. Install the plate between the plates that
have been installed (plates that rub against
the scrapper rail)

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 7. Plate welding
8. Rotate spilage conveyor
9. Position the next scrapper on the tail (total
scrapper are 8 pcs)
10. Conduct trials and monitor the results of
improvements
How Much (How much the % 100%
success to be achieved?)

Sequence Number of 9
Dominant Cause
Dominant Cause There is no bolt tightness frequency monitoring
Why (Why There is no bolt tightness
So that there is a record of the frequency of bolt
frequency monitoring? ) tightening
What (What is the form of repair?)
Monitoring bolt tightness
Where (Where the repair be done?)
311 RE 1
When (When the repair be done?)
1 – 12 Aug 2021
Who(Who is in charge?) Hasan Bisri
Who (Who is in charge?) Steps of Activities:
1. Made monitoring draft.
2. Monitoring print.
3. Monitoring socialization.
4. Monitoring implementation.
How Much (How much the % 100 %
success to be achieved?)

No. Urut Penyebab Dominan 10

Dominant Cause Range Between Chute ECS Bin and Belt 361 WF1
Too Tight.
Why (Why doesn't the canon bin
silica auto star stop control system So that the raw material is not squeezed
have to be repaired?)
What (What is the form of repair?) Widening the Chute
Angle
Where (Where the repair be done?) 361 BI 1
When (When the repair be done?) 14 - 31 Aug 2021
Who(Who is in charge?) Bayu Prianto
Who (Who is in charge?) Steps of Activities:
1. Prepare the tools.
2. Prepare the materials.
3. Cut the side chute as much as 100 mm.
4. Do Welding.
How Much (How much the % 100 %
success to be achieved?)

4.2. 4.3. Setting Intermediate Targets

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 After the group develop an improvement plan from all dominant causes, it can be
determined that the size of the Intermediate target is 100%. this shows the value is the
same as the initial goal value that has been set, which is 100%.

INTERMEDIATE TARGET

310.5
350
300
250
200
100% 100%
150
100
0 0
50
0
Before Repair Initial Goal Intermediate Target

Management comment:

Management approval:

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 DO - Implementing Quality Improvement

1.1. Carrying out Repairs.

1.1.1. Manufacture Stopper On 391 CV 1 – 4 Tension Shaft.

Condition before repairs:

391 CV 1 – 4 tension shaft always
moving which causes the scrapper to
touch the casing so that the scrapper
bends and then the scrapper breaks
which causes the raw mill to block,
this is what causes mechanical
equipment to experience The condition of the 391 CV 1-4 tension
disturbances so that the production shaft which is always moving
process stops.
Repairs Manufacture: Condition after repairs:
Manufacture Stopper on Tension
Shaft –2 & 3 Jun 2021

The condition of the 391 CV 1-4 Tension

Bearing Loose Monitoring
Shaft that never move again
04 - 10 Jun 2021
1

0.9

0.8
Summary:
0.7 Based on the results of monitoring or
0.6 monitoring after repairs have been carried out
QCC QUANTUM – MECHANICAL DEPARTMENT that
0.5
P. 12during
TARJUN KOTABARU-
7 days of monitoring there are no
41
0.4

KALSEL 0.3 more loose bearings due to shifting shaft

0.2
tension. Thus the group concludes that this
repair is SUCCESSFUL.
0.1

0
4 5 6 7 8 9 10
1.1.2. Manufacture a Brace / Support on Harrow Teeth 311 RE1.

Condition before repairs:

Harrow teeth that are not
strong can cause the
harrow teeth to fall off and
fall into the belt so that the
belt is scratched and the
belt becomes torn so that
the raw mil stops which
means that the production
process stops. The condition of Horrow teeth is broken /
not strong

Repairs manufacture: Condition after repairs:

Manufacture a Brace / Support The condition of the harrow teeth is

On harrow teeth on stronger because the brace / support has
11 – 12 Jun 2021. been installed.

Harrow Teeth release monitoring (Times) Summary:

13-19 Jun 2021
After repairs were Manufacture by
1 Manufacture braces/supports on the
QCC QUANTUM
0.9 – MECHANICAL DEPARTMENT P. 12 TARJUN
horrow teeth, KOTABARU-
monitoring the frequency
KALSEL
0.8 of loose horrow teeth was carried out for
7 days with the result that there were no
42
0.7
more loose horrow teeth on the belt so
0.6
that the belt did not tear and the raw mil
 0.4
0.3
0.2
0.1
0
12 13 14 15 16 17 18 19

1.1.3. Increase the height of Damring 361 RM1.

Condition before repairs:

Damring conditions that are

not high enough can cause
raw material to spill which
results in metal touch and mill
vibration so that a lot of
material is spilled and
rejected (cannot be used
anymore). This causes
disruption in the production
process because raw mil Damring distance is too close
must bemanufacture:
Repairs stopped. Condition after repairs:

Increase the height of Damring The damring distance is 0.5 meters

Date : 19 – 20 Jun 2021. higher so that the material does not
spill

Material spills monitoring (Times) 21 - 30 Jun 2021 Summary:

1

0.9
After repairs were manufacture by
0.8
increasing the height of the damring by
0.7
0.5 meters, we monitored the condition
QCC QUANTUM
0.6
– MECHANICAL DEPARTMENT P.after
12 TARJUN KOTABARU-
the repair for 8 days with the result
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43
0.5
that there was no more vibration at raw
0.4
mill so that no more spilled material and
0.3
the raw mill could operate, which means
0.2
that the production process can run well.
0.1
 21 22 23 24 27 28 29 30

1.1.4. Socialization of Bolt Tightness Calculation for Departmental Production

Patroller.

Condition before repairs:

The patroller is in charge of
supervising the production process
equipment, which means that the
patroller is an employee of the
production department who oversees
the mechanical equipment. In the
case of tightening the scrapper bolts,
it is carried out by patrollers who do
not have a background in mechanical
knowledge so they do not know the
level of tightness of the scrapper bolts
which results in the bolts being too
Repairs
tightManufacture
and breaking.: Condition after repairs:
Patroller knows the calculation of bolt
Bolt Tightness Socialization
tightness that for scrapper bolts
For patrollers, 2 – 9 Jun
using M2 with a grade of 8.8 with a
2021 to all group.
firmness level of 411 N/M.

Summary:
After the repair was carried out by
Broken Scrapper Bolt Monitoring on 10 - 30 Jun 2021
1
socializing the tightness of the bolts to the
0.9 patrollers and continued with monitoring
0.8 the tightness of the bolts on the scrapper
0.7 for 19 days with the results of monitoring
0.6 that there were no more broken bolts
0.5 because the tightness was according to
0.4
the 411N/M standard so that there were no
0.3
more broken bolts so that the scrapper
0.2
QCC QUANTUM – MECHANICAL DEPARTMENT P. does not fallKOTABARU-
12 TARJUN and the raw mill can still
0.1
operate smoothly. This
KALSEL 0
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 27 28 29 30
SUCCESSFUL.
44 fix is
4.1.5. Manufacture Planetary Gear System Coupling in 211 AF 1.

Condition before repairs:

When the apron feeder has
problems and has to replace the
planetary gear by cutting, this
manufacture the production
process stop for a long time
because the level of difficulty in
the cutting process is very
difficult. Planetary Gear conditions that are difficult to
cut
Repairs Manufacture: Condition after repairs:
Planetary gear uses a coupling system so
Manufacture planetary gear system there is no need to cut, just open the bolts
Coupling on 3 & 4 Jul 2021. installed

Manufacture process

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 Planetary Gear Fault Monitoring (hours) Summary:
Date : 4 - 11 Jul 2021 After the repair was carried out by
1 Manufacture a planetary gear system
0.9 coupling, then monitoring the results of
the repair was carried out, it was found
0.8
that during the 8 days of monitoring there
0.7 were no more equipment disturbances
0.6 originating from the cut planetary gear so
0.5 that the raw mill could operate properly
and the production process ran smoothly.
0.4
With this improvement, we declare
0.3 SUCCESSFUL
0.2

0.1

0
4 5 6 7 8 9 10 11

4.1.6. Manufacture a Cannopy on 341 SX2.

Condition before repairs:

Sprocket spilled material

Resulting in scrapper load
High so spilage jumping
Causing the chain to break.

Repairs Manufacture: Condition after repairs:

Pembuatan Cannopy di 341 SX2
Manufacture a Cannopy on 341 SX2
sehingga material tidak tumpah ke
10 – 11 Jul 2021.
sprocket .

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 Spillage Jumping Monitoring (times) Summary:
12 - 18 Jul 2021
After repairs are manufacture by
1 Manufacture a canopy on the 341SX2, the
0.9 material does not spill on the sprockets so
that the scrapper load is low and the
0.8
spillage does not jump anymore which
0.7 results in no disruption to the raw mile and
0.6 the production process runs smoothly. This
is known after monitoring for 7 days on
0.5
spillage jumping . Thus the group declares
0.4 that this repair is SUCCESSFUL.
0.3

0.2

0.1

0
12 13 14 15 16 17 18

4.1.7. Manufacture Clamps from Cannal Iron in HD Raw Mill.

Condition before repairs:

The wooden clamp is not strong

enough to cause the HD pipe to
vibrate as a result, the wood clamp is
damaged and the HD pipe is broken
and the HD oil is wasted, resulting in
a stop raw mill and production stops.. Wood Clamp
Repairs Manufacture: Condition after repairs:

Manufacture Clamps from Cannal Iron The clamp is manufacture of cannal

iron so it is stronger and does not break
19 – 20 Jul 2021. anymore..

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 Monitoring the Frequency of Broken Clamps (times) Summary:
on 21 - 27 Jul 2021
1
After repairs are manufacture by
Manufacture iron clamps, the HD pipe
0.9 does not vibrate and the lamp is not
0.8 damaged so that the HD pipe does
0.7
not break and HD oil is not wasted so
that the raw mill does not stop
0.6 production running smoothly. This is
0.5 evidenced by the results of monitoring
the frequency of broken clamps for 7
0.4
days with the result that there are no
0.3 more broken clamps. Thus the group
0.2 declares that this repair is
SUCCESSFUL.
0.1

0
21 22 23 24 25 26 27

4.1.8. Manufacture 311 RE1 Linner Scrapper Support .

Condition before repairs: Bending Liner

The bending of the liner scrapper
causes the guide roller to fall so
that the scrapper abnormally
causes the rail guide roller to
break as a result the rail guide
roller falls so that the raw mill
stops and the production process
stops.
Repairs Manufacture: Condition after repairs:

Manufacture Linner Scrapper Support The liner has been supported so

On 1 & 2 August 2021. it won't bend anymore.

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 Liner Claw Loose Monitoring ( Pcs ) Summary;
3 - 9 August 2021
1
After Manufacture support for the liner
scrapper and monitoring the results for 7
0.9 days, it is known that there is no more
0.8 bent liner scrapper so that the roller
guide does not fall and can run normally
0.7
so that the rail guide does not break and
0.6 does not fall. This is indicated by the
0.5 absence of loose liner nails as in the
results of monitoring. This manufactures
0.4
the raw mill run smoothly so that
0.3 production runs smoothly. Thus the
0.2 group declares that this repair is
SUCCESSFUL.
0.1

0
3 4 5 6 7 8 9

4.1.9. Manufacture Bolt Tightness Frequency Monitoring for Production

Department Patrollers.

Condition before repairs.

Scrapper bolts often break due to

incorrect bolt tightening because
there is no record of the frequency
of tightening. the standard
frequency is 3 times of tightening.

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 Repairs Manufacture: Condition after repairs:
The patroller records the
Manufacture bolt tightness frequency frequency of bolt tightness.
monitoring on 01 – 02 August 2021.

Summary:
Bolt Tightened Frequency Monitoring > 3 Times
03 - 09 August 2021
1
After repairs are manufacture by
0.9 monitoring the frequency of bolt
0.8 tightness, the patroller knows the
0.7 level of frequency of bolt tightness
0.6 and no longer exceeds 3 times in one
0.5 bolt so that there are no more broken
0.4 bolts. This is evidenced by the results
0.3 of monitoring the frequency with
0.2 which the bolts are tightened. Thus
0.1 this repair is declared SUCCESSFUL.
0
3 4 5 6 7 8 9

4.10. Widening the Angle of the Chute ECS Bin.

Condition before repairs:

The distance of the chute that is too

close to the belt causes the raw
material to be squeezed so that the
BC is worn and torn as a result, the
BC sway and raw mill are stopped
from the production process.

Repairs Manufacture: Condition after

repairs: The chute angle is widened by
100 mm
Widen the chute angle on
QCC QUANTUM – MECHANICAL DEPARTMENT P. 12 TARJUN KOTABARU-
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 14 & 15 August 2021.

Wider than before

Equipment Fault Monitoring at Chute Bin (hours) on 16 - 31 August 2021 Summary:

1
After the chute angle is widened and
0.9
the repair results are monitored for
0.8 16 days, there is no longer any
interference with the equipment in the
0.7
chute bin, this is because the
0.6 distance between the chute and the
0.5
belt becomes tenuous so that the raw
material is not pinched and the BC is
0.4 not worn out so that the BC does not
0.3 tear and does not sway so that the
raw material runs smoothly. and the
0.2
production process operates well.
0.1 Thus, the group agreed that this
repair was SUCCESSFUL.
0
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

IV. CONFIRMATION OF RESULT

Period : Week I – IV September 2021

1. Analysis of Repair Results

1.1. Analysis of Changes in Conditions on the Dominant Cause:

1.1.1. Cause of 391 CV 1- 4 Shaft Tension Moved

Data Source : Check sheet
Data Collector : Hasan Bisri.

Before After
Date Bearing Shaft Date Bearing Shaft
Release Release
Frequency Frequency
10-04-2021 1 04-06-2021 0
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51
 11-04-2021 0 05-06-2021 0
12-04-2021 4 06-06-2021 0
13-04-2021 1 07-06-2021 0
14-04-2021 1 08-06-2021 0
15-04-2021 0 09-06-2021 0
16-04-2021 0 10-06-2021 0
17-04-2021 3
18-04-2021 1
19-04-2021 2
20-04-2021 2
21-04-2021 3
22-04-2021 1
23-04-2021 1
24-04-2021 2
Total 22 0

Changes in Conditions to the Cause of 391 CV 1-4 Shaft Summary:

Tension moved
There is a change in conditions to
22 the dominant cause of 391 CV 1 - 4
Shaft Tension moved, before repair
25
there were 22 loose shaft bearings
20
while after repair there were no
loose shaft bearings. Thus, this
15 cause can be eliminated with the
correct idea of repairing what has
0
10
been done by QCC Quantum,
5
namely manufacture a stopper
shaft tension.
0
Before After

1.1.2. Cause of 311 RE1 Harrow Teeth is not strong enough.

Data Source : Cheeck Sheet.

Data Collector : Suparto

Before After
Date Number of Horrow Date Number of Horrow
Teeth Released Teeth Released
( Pcs ) ( Pcs )
01-04-2021 2 12-06-2021 0
02-04-2021 2 13-06-2021 0
03-04-2021 4 14-06-2021 0
04-04-2021 2 15-06-2021 0
05-04-2021 0 16-06-2021 0
06-04-2021 1 17-06-2021 0
07-04-2021 1 18-06-2021 0
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52
 08-04-2021 4 19-06-2021
09-04-2021 2
10-04-2021 2
11-04-2021 0
12-04-2021 0
13-04-2021 6
14-04-2021 1
15-04-2021 2
Total 29 0

Changes in Condition to Harrow Teeth Not Strong

Cause
29

30

25

20

15

10 0
5

0
Before After

Summary: There is a change in the condition of the cause of the 311 RE1 harrow
teeth not being strong, before the repair there were 29 pcs of harrow teeth loose,
while after the repair there were no more horrow teeth loose. It can be concluded that
the idea of Manufacture braces / support is the right improvement from QCC
Quantum.
1.1.3. Cause of 361 RM1 Damring is not high enough.

Data Source : Check Sheet.

Data Collector : Bayu Prianto.

Before After
Date Frequency of Date Frequency of
Spilled Material Spilled Material
( Times ) ( Times )
01-05-2021 2 21-06-2021 0
02-05-2021 2 22-06-2021 0
03-05-2021 4 23-06-2021 0
04-05-2021 2 24-06-2021 0
05-05-2021 0 27-06-2021 0
06-05-2021 1 28-06-2021 0
07-05-2021 1 29-06-2021 0

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53
 08-05-2021 4 30-06-2021
09-05-2021 2
10-05-2021 2
11-05-2021 0
12-05-2021 0
13-05-2021 6
14-05-2021 1
15-05-2021 2
Total 32 0

Changes in Conditions Cause of Damring 361 RM1 is Not High

32
35

30

25

20

0
15

10

0
Before After

Summary: There is a change in conditions to the cause of Damring 361 RM1 not
being high enough, before the repair there were 32 times the material was spilled,
while after the repair was carried out there was no more spilled material. It can be
concluded that the idea of increasing the height of the damring is the right
improvement from QCC Quantum.
1.1.4. Cause of Patroller is not from Mechanic.

Data Source : Check Sheet.

Data Collector : Hasan Bisri.
Before After
Date Number of Broken Date Number of Broken
Bolts (Pcs) Bolts (Pcs)
15-05-2021 4 10-06-2021 0
16-05-2021 8 11-06-2021 0
17-05-2021 7 12-06-2021 0
18-05-2021 5 13-06-2021 0
19-05-2021 8 14-06-2021 0
20-05-2021 3 15-06-2021 0
21-05-2021 5 16-06-2021 0
22-05-2021 10 17-06-2021 0
23-05-2021 6 18-06-2021 0

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 24-05-2021 2 19-06-2021 0
20-06-2021 0
21-06-2021 0
22-06-2021 0
23-06-2021 0
24-06-2021 0
25-06-2021 0
26-06-2021 0
27-06-2021 0
28-06-2021 0
29-06-2021 0
30-06-2021 0
Total 58 0

Changes in Conditions to the Cause of Patroller Not Mechanic

58
60

50

40

30

20
0
10

0
Before After

Summary: There is a change in conditions to the cause of the non-mechanic

patroller, before the repair there were 58 pcs of broken bolts, while after the repair
was carried out there were no more broken bolts. It can be concluded that the idea of
improving the socialization of the calculation of bolt tightness to the patroller is an
appropriate improvement from the QCC Quantum.
1.1.5. Cause of Shaft Output stick on Apron Feeder.

Data Source : Check Sheet

Data Collector : Suparto.

Before After
Date Equipment Date Equipment
Disturbance Disturbance
(hours) (hours)
15-05-2021 2 04-07-2021 0
16-05-2021 2 05-07-2021 0
17-05-2021 4 06-07-2021 0
18-05-2021 1 07-07-2021 0
19-05-2021 0 08-07-2021 0
20-05-2021 0 09-07-2021 0
21-05-2021 2 10-07-2021 0
22-05-2021 1 11-07-2021 0
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 23-05-2021 1
24-05-2021 2
Total 15 0

Changes in Conditions to the Cause of the Output Shaft At -

tached to the Apron Feeder

15
16
14
12
10
8
6
4
0
2
0
Before After

Summary: There is a change in conditions to the cause of the output shaft being
attached to the apron feeder, before the repair there were 15 hours of equipment
disturbance, while after the repair was carried out there was no more equipment
disturbance from this cause, so it can be concluded that the idea of Manufacture a
planetary gear coupling system is the right improvement from QCC Quantum.
1.1.6. Cause of 341 SX2 Sprocket spilled by materials.

Data Source : Check Sheet.

Data Collector : Hasan Bisri.

Before After
Date Spillage Jumping Date Spillage Jumping
Frequency (times) Frequency (times)
01-05-2021 4 12-07-2021 0
02-05-2021 2 13-07-2021 0
03-05-2021 2 14-07-2021 0
04-05-2021 2 15-07-2021 0
05-05-2021 3 16-07-2021 0
06-05-2021 1 17-07-2021 0
07-05-2021 1 18-07-2021 0
08-05-2021 2
09-05-2021 4
10-05-2021 2
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 Total 23 0

Changes in Conditions to the Cause of 341 SX2 Sprocket

Spilled by Material

23
25

20

15

10
0
5

0
Before After

Summary: There was a change in conditions that caused material spillage of the 341
SX2 sprocket, before the repair there were 23 spillage jumping, while after the repair
was carried out there was no more spillage jumping, so it can be concluded that the
idea of Manufacture a cannopy on the 341 SX2 is the right improvement from QCC
Quantum.

1.1.7. Cause of HD Wood Pipe Clamp is not strong enough.

Data Source : Check Sheet.

Data Collector : Bayu Prianto.

Before After
Date Fracture Clamp Date Fracture Clamp
Frequency( times ) Frequency( times )
1st week of May 4 21-07-2021 0
2021
2nd week of May 2 22-07-2021 0
2021
3rd week of May 2 23-07-2021 0
2021
4th week of May 3 24-07-2021 0
2021
25-07-2021 0
26-07-2021 0
27-07-2021 0
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 Total 11 0

Changes in Conditions on the Causes of HD Pipe Wood Clamps

Are Not Strong

11
12

10

4 0
2

0
Before After

Summary: There was a change in conditions that caused the HD pipe wood clamp
to be not strong, before repair there were 11 broken clamps, while after the repair
was carried out there were no more broken clamps, so it can be concluded that the
idea of Manufacture iron clamps from cannal iron is the right improvement from QCC
Quantum.

1.1.8. Cause of 311 RE 1 Linner Scrapper is easy to bent.

Data Source : Check Sheet.

Data Collector : Suparto.

Before After
Date Number of Loose Date Number of Loose
Scrapper Linner Scrapper Linner
Claws (Pcs) Claws (Pcs)
03-04-2021 4 03-08-2021 0
04-04-2021 4 04-08-2021 0
05-04-2021 1 05-08-2021 0
06-04-2021 0 06-08-2021 0
07-04-2021 1 07-08-2021 0
10-04-2021 4 08-08-2021 0
11-04-2021 2 09-08-2021 0
12-04-2021 2
13-04-2021 0
14-04-2021 1
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 15-04-2021 2
16-04-2021 3
17-04-2021 2
18-04-2021 4
19-04-2021 3
Total 33 0

Changes in Conditions on the Causes of 311 RE 1 Linner

Scrapper Easily Bend
33
35

30

25

20

15

10
0
5

0
Before After

Summary: There was a change in conditions that caused the 311RE1 liner scrapper
to bend easily, before the repair there were 33 loose linner scrapper nails, while after
the repair was carried out there were no more loose linner scrapper nails, so it can
be concluded that the idea of Manufacture a support liner scrapper is the right
improvement from QCC Quantum.
1.1.9. Cause of no bolt tightness monitoring.

Data Source : Check Sheet.

Data Collector : Hasan Bisri.
Before After
Date Frequency of bolts Date Frequency of bolts
tightened > 3 tightened > 3
times ( Times ) times ( Times )
15-03-2021 5 03-08-2021 0
16-03-2021 6 04-08-2021 0
17-03-2021 7 05-08-2021 0
18-03-2021 4 06-08-2021 0
19-03-2021 3 07-08-2021 0
20-03-2021 2 08-08-2021 0
21-03-2021 1 09-08-2021 0
22-03-2021 8
23-03-2021 9
24-03-2021 2
Total 47 0

QCC QUANTUM – MECHANICAL

Changes DEPARTMENT
in Conditions to the CauseP.
of12No
TARJUN KOTABARU-
Monitoring of Bolt
KALSEL Tightness 59
47
 45
40
35
30
25
20
15
0
10
5
0
Before After

Summary: There is a change in conditions causing no monitoring of bolt tightness,

before repair there were 47 bolts tightened more than 3 times, while after repairs
were carried out no more bolts were tightened more than 3 times, so it can be
concluded that the idea of repairing bolt tightness monitoring is an improvement. right
from QCC Quantum.

1.1.10. Cause of Distance Between ECS Bin and Belt 361WF1 Too Close.

Data Source : Check Sheet.

Data Collector : Bayu Prianto.

Before After
Date Equipment Date Equipment
Disturbance Disturbance
(hours) (hours)
03-04-2021 5 16-08-2021 0
04-04-2021 5 17-08-2021 0
05-04-2021 47.5 18-08-2021 0
06-04-2021 4 19-08-2021 0
07-04-2021 4 20-08-2021 0
10-04-2021 3 21-08-2021 0
11-04-2021 2 22-08-2021 0
12-04-2021 2.5 23-08-2021 0
13-04-2021 1 24-08-2021 0
14-04-2021 0 25-08-2021 0
15-04-2021 0 26-08-2021 0
27-08-2021 0
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 28-08-2021 0
29-08-2021 0
30-08-2021 0
31-08-2021 0
Total 31.25 0

Changes in Conditions on the Causes of the Distance Between

ECS Bin and Belt 361 WF1 Too Close

31.25
35

30

25

20

0
15

10

0
Before After

Summary: There was a change in conditions causing the distance between the ECS
bin and the 361 WF1 belt to be too tight, before the repair there were 31.25 hours of
equipment disruption in the bin, while after the repairs were carried out there were no
more equipment disturbances in the bin, so it can be concluded that the idea of
widening the chute angle is a good improvement. right from QCC Quantum.
1.2. Comparative Analysis of Results Against Title

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 Material
Shortage
Summary: From the data table and Pareto diagram above, it is known that before the repair was
carried out, precisely in January 2021, there was a production process disruption or downtime in the
raw mill with the highest frequency level being mechanical equipment 8 times. After the repairs were
carried out, precisely in September 2021, there were disruptions in the production process in the raw
mill with the highest frequency occurring in material shortages as much as 6 times, while the
downtime of the production process in the raw mill from mechanical equipment did not occur again,
thus downtime from mechanical equipment could be reduced by up to 100%.

Total Total

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Summary: From the data table and Pareto diagram above, it is known that before the repair
was carried out, precisely in January 2021, there was a production process disruption or
downtime in the raw mill with the longest duration being mechanical equipment for 310.5
hours. After the repairs were carried out, precisely in September 2021, there was a disruption
in the production process in the raw mill with the longest duration occurring in material
shortage for 112 hours, while the downtime of the production process in the raw mill from
mechanical equipment did not occur again, thus downtime from mechanical equipment could
be reduced by up to 100%.

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 Summary: From the data table and Pareto diagram above, it is known that before the
repairs were carried out, precisely in January 2021, there was a production process
disruption or downtime in the raw mill which resulted in the largest loss of cement
production due to disturbances in mechanical equipment as much as 152,515.24 tons. .
After the repairs were carried out, precisely in September 2021, there was a disruption in
the production process at the raw mill with the most lost production occurring in material
shortage as much as 55,013.55 tons, while lost cement production from mechanical
equipment disruptions did not occur again, thus lost production from mechanical
equipment could be reduced to 100%.

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 Summary: From the data table and Pareto diagram above, it is known that before the
repair was carried out, precisely in January 2021, there was a disruption in the
production process or downtime at the raw mill which resulted in the loss of the largest
lost cost of cement production due to disturbances in mechanical equipment worth Rp.
70,157,012,195.00 . After the repairs were carried out, precisely in September 2021,
there was a disruption in the production process at the raw mill with the most lost cost
cement production occurring in material shortages worth Rp. 25,306,233,062.00 , while
the lost cost of cement production from mechanical equipment disturbances no longer
occurs, thus the lost cost of cement production from mechanical equipment can be
reduced to 100%.
2.1. Comparison of Results Against Target.

Comparison of Results Against Target

8
8

3
100 % 100 % 100 %
2

1
0 0 0
0
Before Initia Goal Intermediate Target After

2.2. Comparison of Results Against Themes.

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QCC QUANTUM – MECHANICAL DEPARTMENT P. 12 TARJUN KOTABARU-
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QCC QUANTUM – MECHANICAL DEPARTMENT P. 12 TARJUN KOTABARU-
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 Before Repairs

After Repairs
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68
Summary:
Based on the data above, QCC QUANTUM has succeeded in reducing down time in raw
mills, both from the number of disturbances, the duration of the disturbance, raw mill lost
product, clinker lost product, cement lost product, as well as the loss value of lost benefit
production..
Comparison of Results Against KPM Mechanical Department:

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3.1. Repair Impact Analysis
Positive Impact:
Tangible:

1. Raw mill down time due to mechanical equipment disturbances can be

eliminated
2. Cement Production Increase.
3. Reducing cement rejects, torn belts, purchasing gear boxes,
4. The cost savings that can be obtained in one month are as follows:

No Loss Type Loss Value

1 Lost Cost Production Benefit Rp. 70,157,012.195.00
2 Replace Planetary Gear Apron Rp 19,600,000,000.00
Feeder
3 Replace Scrapper Rp. 10,000,000.00
4 Resplicing Rp. 3,080,000.00
5 Replace Chain Rp. 40,000,000.00
6 Loss HD Oil Rp. 225,000.00
7 Cement Reject Rp. 2,300,000.00
Cost Saving Total Rp. 89,812,617,195.00

Intangible:
1. Reducing the risk of employee accidents
2. Increase employee motivation, knowledge and work experience
3. Improve the relationship between superiors and subordinates as well as
between QCC members.
Efforts Manufacture:
1. Socialization of improvement results to other QCC.
2. Socialization of the results of improvements to the production employees of the Raw
Mill
Negative Impact:
1. The location/position of the spillage disintegrator above the apron feeder hopper is
in an open condition so it is very dangerous for the spillage motor inspector
because the disintegrator rotates continuously.
2. The sound emitted by the big blaster/air canon is so loud that it can cause a shock
to field officers.
Efforts Eliminating Negtive Impact : :

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 1. Considering that the position of the disintegrator must be open in order to facilitate
maintenance and inspection, signs or barriers prohibiting limited areas other than
officers are Manufacture.
2. Immediately manufacture signs for the use of PPE ear muffs and be careful when
crossing the area.
3.2. QCC Performance
QCC performance data sheet and work site quality after repairs

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71
 Summary:
From the data sheet and radar chart
above, it shows that the QCC
performance average score is 3.30 while
the average score for the quality of the
work site is 3.67. From the data sheet
and Rinda window above, it shows that
the QCC performance and the quality of
the work site after carrying out work
repairs are in zone B, meaning that the
quality of the work site and QCC
performance are good after carrying out
PDCA activities..

V. STANDARDIZATION
Period : Week I – IV October 2021

1. Standard Procedure
1.1. Standard procedure for Manufacturing & Maintenance of Raw Mill
Mechanical Equipment according to P12/OPD-PR/K3/01
procedures

1.1.1.1 Modify the apron mix rail and shaft sprocket mount
1.1.1.2 Modify the shape of the disintegrator blade
1.1.1.3 Manufacture a canopy sprocket chain spillage conveyor apron mix

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 1.1.1.4 Modify the lip elevation of the chute weight feeder raw mix
1.1.1.5 Modify the lip elevation of the limestone chute weight feeder.
1.1.1.6 Modify the lips of the casing chute raw mix with a round bar
1.1.1.7 Modify the lip of the casing chute limestone with a round bar
1.1.1.8 Modify the 341SX2 spillage scrapper by adding a plate to the scrapper
1.1.1.9 Install the air cannon in the silica bin
1.1.1.10 Manufacture automatic air cannon start stop panels in the silica bin
1.1.1.11 Install the anti-sticky material (kalen) on the casing in the silica bin
1.1.1.12 Install anti-sticky material (kalen) on the casing in the laterite bin

1.2. Standard operating procedures according to P12/OPD-PR/K3/01

procedures

1.2.1.1. Perform operations using apron mix rails and shaft sprocket mounts
1.2.1.2. Perform the operation of the new disintegrator blade
1.2.1.3. Perform the operation of the lip elevation chute weight feeder raw mix
1.2.1.4. Carry out the principle operation of the chute weight feeder limestone lip
elevation
1.2.1.5. Perform the operation of using the lip casing chute raw mix with a round bar.
1.2.1.6. Perform the operation of the chute limestone casing lip with a round bar.
1.2.1.7. Perform the operation of the 341SX2 spillage scrapper operation
1.2.1.8. Carry out the principal operation of the air cannon in the silica bin.
1.2.1.9. Carry out the operation using the automatic air cannon start stop panel in the
silica bin

1.3. Standard maintenance procedures according to

P12/OPD-PR/K3/01

6.1.3.1. Perform maintenance on the apron mix rails and shaft sprocket mounts.
6.1.3.2. Perform new disintegrator blade maintenance
6.1.3.3. Perform maintenance on canopy sprocket chain spillage conveyor apron mix
6.1.3.4. Do lip elevation treatment chute weight feeder raw mix.
6.1.3.5. Do lip elevation treatment of chute weight feeder limestone.
6.1.3.6. Take care rawmix chute casing lip with round bar
6.1.3.7. Do the casing chute limestone lip treatment with a round bar
6.1.3.8. Perform 341SX2 spillage maintenance
6.1.3.9. Do water cannon treatment in silica bin
6.1.3.10. Perform maintenance on the automatic air cannon start stop panel in the silica
bin
6.1.3.11. Take care of the anti-sticky (kalen) material on the casing in the silica bin
6.1.3.12. Take care of the anti-sticky (kalen) material on the casing in the laterite bin

2. Result Standard
By consistently carrying out the above procedures, the Mechanical Equipment
down time in Raw Mill Plant 12 is a maximum of 0 times in one month

3. New Standard Implementation Strategy.

Endorsement & Socialization Plan

Activity Plan Realization
P.I.C. Description
Date Date
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73
Editorial Preparation 04/09/2021 02/10/2021 Bayu Done
Endorsement 11/09/2021 09/10/2021 Hasan Done
Socialization 13-20/9/2021 11-18/10/2021 Suparto Done

Management's Endorsement and Approval,Plant Site, 26 October 2021

4. Advantages of Implementing New Standards :

1. Downtime raw mill due to mechanical equipment disruption can be eliminated

2. Reducing cement rejects, torn belts, buying gear boxes,
3. Reduce employee work risk
4. Reducing company losses due to mechanical equipment damage on the apron
feeder in the raw mill dosing hopper
5. The cost savings that can be obtained in one month are as
follows::

No Loss Type Loss Value

1 Lost Cost Production Benefit Rp. 70,157,012.195.00
2 Replace Planetary Gear Apron Rp 19,600,000,000.00
Feeder
3 Replace Scrapper Rp. 10,000,000.00
4 Resplicing Rp. 3,080,000.00
5 Replace Chain Rp. 40,000,000.00
6 Loss HD Oil Rp. 225,000.00
7 Cement Reject Rp. 2,300,000.00
Cost Saving Total Rp. 89,812,617,195.00

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 VI. FURTHER ACTION
Period: October 2021 – January 2022
1. Evaluation of Standard Consistency of Results

Monitor and maintain the standard of results that have been achieved in the
previous step.

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 2. Monitoring Of Consistency Standard Result Downtime
Mechanical Equipment In Raw Mill

Summary : Based on the results of observations on the monitoring of standard results

for each measurement of the problem, it can be seen that each problem with the
equipment for a period of 4 months does not occur anymore. Meanwhile, the monitoring
of standard results on mechanical equipment disturbances which is a problem with the
title, it is known that within 4 months there will be no more mechanical equipment
disturbances in the raw mill. Thus, QCC managed to maintain the consistency of the
standard results by carrying out the procedures that have been manufacture.

3. Replication of Repair Results:

3.1. In addition to the installation of Planetary Gear Couplings in 211 AF1

(Mining Area) which is the result of improvement, the improved plantery

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77
 gear coupling has also been installed in 531 AF1 and 341 AF 2 (Plant
area) in different locations.

3.2. In addition to socializing the size

of the scrapper bolt tightness by QCC Quantum from mechanic to patroller
in the production division, QCC Quantum also conducted socialization to
employees who work in the Jetty Dispatch Dept. for measuring flexible joint
bolts that have the same size as scrapper bolts, namely M20 bolts with
grade 8.8 with a firmness level of 411N/M. The socialization will be held on
13 & 14 October 2021.

3.3. Manufacture braces / support for harrow teeth is not only applied to
311RE1 but also to 331 RE1 & RE2. The similarity between 311 RE1 and
3311RE1 & RE2 is that it is a reclaimer tool for scratching or leveling
materials. The difference is the type of material in 311 RE1 is Limestone,
while the type of material in 331 RE1 & 2 is gypsum. Brace/uspport
installation at 331 RE1 & RE2 will be held on 22 & 23 October 2021.

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4. Collecting New Data
4.1. Determining the Theme
4.1.1. Down time frequency data based on work area

Data Source : Daily shut down report

Data Period : January 2022
Data Collector : Hasan Bisri
Purpose : To find out down time frequency
Unit : Times

6
(Kali)

5
5
4
4
Frekuensi gangguan

3
3

0
Raw Mill Finish Mill 1 & 2 Kiln

4.1.2. Down time Duration Data based on work area

Data Source : Daily shut down report

Data Period : January 2022
Data Collector : Hasan Bisri
Purpose : To find out down time duration
Unit : Hours

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 4.1.3. Raw Mill lost product Data

Data Source : Daily shut down report

Data Period : January 2022
Data Collector : Hasan Bisri
Purpose : To find out raw mill lost product value
Unit : Ton

4.1.4. Cement lost product data

Data Source : Daily shut down report

Data Period : January 2022
Data Collector : Hasan Bisri
Purpose : To find out cement lost product value
Unit : Ton

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 4.1.5. Lost product’s loss value data

Data Source : Daily shut down report

Data Period : January 2022
Data Collector : Hasan Bisri
Purpose : To find out lost product’s loss value
Unit : Rupiah

Pareto Analysis:

1. From the data sheet and bar chart on the down time frequency based on the work area
above, it can be seen that the Raw mill area experiences the most down time 5 times in
one month.
2. From the data sheet and bar chart on the duration of down time based on the work area
above, it can be seen that the Raw Mill area experienced the longest down time of 13.66
hours in one month.
3. From the data sheet and bar chart on the potential Raw Mill lost product above, it can be
seen that Raw mill down time has the biggest influence on the loss of Raw Meal production
of 7,922.80 Tons or 58.15% in one month.
4. From the data sheet and bar chart on Cement lost product above, it can be seen that Raw
mill down time has the biggest influence on the loss of cement production of 6,709.69 tons
or 87.17% in one month.
5. From the data sheet and bar chart on the value of lost product losses above, it can be seen
that Raw mill down time has the biggest influence on the loss of cement production
revenue of Rp. 3,086.456,639.57, - or 87.17% in one month.

Thus, Raw Mill down time is a priority issue, and QCC Quantum agreed to set the theme:
“Eliminate Raw Mill Down Time in Plant 12 Tarjun ”
Schedule of Action Plans for 2022

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 Approved By:

Bilter Sinaga.
Facilitator

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