CASE STUDY ABOUT CAUSE ANALYSIS OF PACKER

MACHINE 66L-PM1 JAMMED

CASE STUDY

STATE POLYTECHNIC OF JAKARTA – PT. SOLUSI BANGUN

INDONESIA TBK CILACAP PLANT

AHMAD USAIRI
NIM: 2002315046
FIRGINA SYAKURA RAMADHANI
NIM : 2002315027

STATE POLYTECHNIC OF JAKARTA-EVE PT SOLUSI BANGUN

INDONESIA
MAJORING IN MECHANICAL ENGINEERING
CONCENTRATION OF ENGINEERING INDUSTRY
CILACAP
2022
 PNJ-PT. SOLUSI BANGUN INDONESIA TBK PABRIK CILACAP

CASE STUDY ABOUT CAUSE ANALYSIS OF PACKER

MACHINE 66L-PM1 JAMMED

This report is prepared to fulfill one of the requirements for completing the fourth
semester learning process of the Mechanical Engineering Study Program
In the Department of Mechanical Engineering in Industrial Engineering

CASE STUDY

From:
Ahmad Usairi NIM. 2002315046
Firgina Syakura Ramadhani NIM. 2002315027

STATE POLYTECHNIC OF JAKARTA

2022
 APPROVAL SHEET

CASE STUDY ABOUT CAUSE ANALYSIS OF PACKER

MACHINE 66L-PM1 JAMMED

By:

Ahmad Usairi NIM. 2002315046

Firgina Syakura Ramadhani NIM. 2002315027

This paper is declared ready for trial

Cilacap,

Advisor 1 Advisor 2

Silo Wardhono, ST. M. Si Agus MU

NIP. 1962 05 171988031002 NIK. 62201067

Examiner

Fatahula, S.T., M. KOM

NIP. 196808231994031001

iii
 PREFACE

Praise and gratitude we pray to the presence of God Almighty, because of

His blessings and grace we were able to complete a case study with the title: Case
Study of the Cause of Broken Buttom Bearing in Packer Machine 66L-PM1. The
author chose Packer Machine 66L-PM1 as the topic of the case study.

This proposal was made in order to complete one of the requirements for
the Enterprise based Vocational Education (EVE) education curriculum, namely
completing the learning process in the fourth semester of the Mechanical
Engineering Study Program, Department of Mechanical Engineering, Industrial
Engineering at the Jakarta State Polytechnic.

This case study proposal was made with various kinds of research and
assistance from various parties that helped solve challenges and problems in the
work process. This case study report contains information about the data on the
cause of the broken bottom bearing on the 66L-PM1 packer machine.

We believe that this report is not spared from various shortcomings. We are
very happy when there are criticisms and suggestions from readers to further
complete this report.

Finally, we would like to thank all those who have helped, supported, and
participated in the preparation of this report. Hopefully this report can be useful
someday.

Cilacap, August 2022

Writer Team

iv
 LIST OF CONTENT

APPROVAL SHEET ............................................................................................ ii

PREFACE ............................................................................................................. iii
LIST OF CONTENT ............................................................................................ v
LIST OF FIGURE...................................................................................................
LIST OF TABLE.....................................................................................................
CHAPTER I INTRODUCTION ........................................................................ 1
1.1 Background.......................................................................................................1
1.2 Problems ...........................................................................................................2
1.3 Boundary Problems..........................................................................................2
1.4 The Purpose of Making Case Study ................................................................3
1.5 The Benefits of Making Case Study……………………………………………………………….4

1.6 Writing System……………………………………………………………………………………………..5

1.7 Location of Research ........................................................................................5

CHAPTER II LITERATURE REVIEW ........................................................... 6
2.1. Packing Cement.....................................................................................................6
2.2. Cement ...................................................................................................................6
2.3. Packer Machine .....................................................................................................7
2.4. Packer Machine in PT Solusi Bangun Indonesia Tbk ...................................... 10
2.5. Packer Machine Mod. Ge “Plus” ....................................................................... 11
2.6. The Main Characteristic Packer Machine 66L-PM1 ....................................... 11
2.7. Key Component of Packer Machine 66L-PM1 ................................................. 12
2.8. Safety Improvement ............................................................................................ 22
2.9. Work Cycle of Packer Machine 66L-PM1......................................................... 22
2.10. Special Spesification of Packer Machine 66L-PM1 ........................................ 26
2.11. Pneumatic System 66L-PM1 ............................................................................ 28
2.12. Hydraulic System 66L-PM1 ............................................................................. 30
2.13. Maintenance ...................................................................................................... 32
2.14. Bearing ............................................................................................................... 35
CHAPTER III METHODOLOGY .................................................................. 45
3.1 Problem Resolution Method ................................................................................ 45
CHAPTER IV DATA AND ANALYSIS.......................................................... 47
4.1 Main Problem Analysis of Broken Bearing on 66L-PM1 ............................ 47

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 4.2 Problem Finding Analysis .............................................................................. 49
CHAPTER V CONCLUSION AND RECOMMENDATION ........................ 56
5.1 Conclusion....................................................................................................... 57
5.2 Recommendation ............................................................................................ 58
BIBLIOGRAPHY
ATTACHMENT

vi
 LIST OF FIGURE

FIGURE 1.7 CEMENT PRODUCTION FLOWSHEET 1 ................................................... 5

FIGURE 2.2 PACKER MACHINE 1............................................................................... 7
FIGURE 2.3 ROTARY PACKER MACHINE 1 ................................................................ 9
FIGURE 2.5 PACKER MACHINE MOD.GE “PLUS” 1 ................................................. 11
FIGURE 2.7 KOMPONEN PENTING PACKER MACHINE 66L-PM1 1 .......................... 12
FIGURE 2.7.2 ELECTRIC COLLECTOR 1 ................................................................... 13
FIGURE 2.7.3 MECHANIC MAGIX BOX 1 ................................................................. 13
FIGURE 2.7.4 ROTATION REDUCTION GEAR 1......................................................... 14
FIGURE 2.7.5 CYLINDRICAL TANK 1 ........................................................................ 15
FIGURE 2.7.6 LEVEL INDICATOR 1 .......................................................................... 15
FIGURE 2.7.7 CELL FEEDER 1 ................................................................................. 16
FIGURE 2.7.8 THROTTLE VALVE 1 .......................................................................... 16
FIGURE 2.7.9 SETTING DEVICES GROUP 1 .............................................................. 17
PICTURE 2.7.10 PUMP GROUP 1 ............................................................................. 18
FIGURE 2.7.12.1 BAG HOLDER UNIT 1 ................................................................... 19
PICTURE 2.7.12.2 CHARGING CYCLE IN BAG 1....................................................... 20
PICTURE 2.7.13 LOWER SUPPORT 1 ........................................................................ 20
FIGURE 2.7.14 CONTROL GROUP 1 ......................................................................... 21
FIGURE 2.7.15 CHARGING SPOUT 1 ........................................................................ 22
FIGURE 2.8 SAFETY IMPROVEMENT 66L-PM1 1 ..................................................... 22
FIGURE 2.9 WORKING CYCLE 66L-PM1 1 .............................................................. 23
FIGURE 2.11.1 CONNECTION PNEUMATIC 66L-PM1............................................... 28
FIGURE 2.11.3 PNEUMATIC CONNECTION 66L-PM1 .............................................. 29
FIGURE 2.11.4 PNEUMATIC DIAGRAM 66L-PM1 .................................................... 30
FIGURE 2.7.11 GREASE SYSTEM ............................................................................. 38
FIGURE 2.12.2 BALL BEARING 66L-PM1 1 ............................................................ 33
FIGURE 4.5.1 SCHEME ENTERING GREASE 66L-PM1 ............................................... 50

vii
 LIST OF TABLE

TABLE 2.10.1 CONFIGURATION OF 66L-PM1 1 ...................................................... 25

TABLE 2.10.2 COMPRESSED AIR 66L-PM1 1 .......................................................... 25
TABLE 2.10.3 CAPACITY 66L-PM1 1 ..................................................................... 25
TABLE 2.10.4 WORKING TEMPERATURES 66L-PM1 .............................................. 25
TABLE 2.10.5 DYNAMIC LOAD 66L-PM1 1 ........................................................... 26
TABLE 2.10.6 SPESIFIKASI KHUSUS 66L-PM1 1 .................................................... 26
TABLE 2.12.2 TECHNICAL DATA BEARING 66L-PM1 ............................................ 34
TABLE 2.12.2 MANUAL BOOK BEARING 1 ............................................................ 35

viii
 CHAPTER I
INTRODUCTION

1.1 Background
PT Solusi Bangun Indonesia Tbk is a cement company that is
committed to being a leading company in Indonesia. PT Solusi Bangun
Indonesia Tbk runs an integrated business of cement, ready mix concrete, and
aggregate production. The Company operates four cement factories on site,
namely Narogong (West Java), Cilacap (Central Java), Tuban (East Java), and
Lhoknga (Aceh) with a total capacity of 14.5 million tons of cement per year.
This is very dependent on the production capacity which is the main target in
generating benefits. And the cement production process cannot be separated
from the stable performance of production equipment in all areas of the
factory, one of which is the Packhouse area[1].

The packhouse area is one of the areas in the factory that really
determines the success of the factory in marketing cement products
produced by the factory to get benefits. This area is the final process of the
cement production process, where the cement will be packaged in a cement
bag before it reaches the consumer. The final result of the production
process is in the form of a bag of cement that has gone through the packing
stage. The packing process is carried out by weighing the weight of cement
in each bag of cement according to the dose and using a system made to
facilitate the production process according to the target.

Packer machine is a unit of cement packaging equipment at the final

stage in the cement production process before being released to the market.
In this case, the packer machine is one of the important equipment in
meeting the smoothness and production needs of PT Solusi Bangun
Indonesia Tbk. The packer machine we use is a ventomatic packer machine,
made by FLSmidth. This packer machine is a rotary packer machine.
Where, every rotation of this machine there are eight spouts for filling bags
with a combination of automated sensors.

1
 In the packing process, automation is carried out by the bag
applicator which automatically takes the bag from the cement bag machine,
then applies it to each spout of the rotary packer machine for cement filling
based on the ventodigit dose. All filling units on the rotary packer are
connected to the canbus data network via an optical connection system, all
weighing units are also connected with an encoder to the operator panel.

Apart from dynamix cement, this cement company also produces

other cements, such as Padang cement and Gresik cement. Cement dynamix
is the main cement product produced by PT Solusi Bangun Indonesia Tbk.
In the packing process, the 66L-PM1 packer machine is one of 8 similar
equipment, located in the packhouse area of the PT Solusi Bangun Indonesia
Tbk factory. This 66L-PM1 packer machine still uses pneumatics and
blowers as the driving medium. During this time, from year to year in
operation, this packer machine often experiences problems or disturbances
during its operation.

At the end of November in 2021, one of the packer machines

experienced a long stop due to an unscheduled breakdown in the Packhouse
area which was dominated by mechanical trouble and production trouble
which reached 279.20 hours, causing huge losses for cement companies,
where equipment the problem is the Button Bearing Packer Machine 66L-
PM1.

From a brief review of the problems above, this case study focuses
on the problem that causes the 66L-PM1 Buttom Bearing Packer Machine
to fail, where the main problem analyzed is the cause of the 66L-PM1
Packer Machine experiencing unscheduled breakdown (jammed). Damage
to the bottom bearing is a very critical problem because it can have an
impact on the delay in packing the cement production at PT Solusi Bangun
Indonesia Tbk.

1.2 Problems
Based on the background and objectives that have been explained,
the formulation of the problem that must be resolved is as follows:

2
 1. How to Find the Cause of Packer Machine Jammed on the 66L-PM1?
2. How to determine the effect of the buttom bearing on the performance of
the packer cement machine 66L-PM1 and subsequent equipment?
3. How to optimize the performance of the packer machine 66L-PM1 so as
not to get jammed?

1.3 Boundary Problems

So that the discussion in this case study does not widen, the research
in this case study has a problem limitation, namely:

1. The cause of dust build-up on the impeller of packer machine 66L-PM1

in terms of the mechanical.
2. The cause of dust build-up on the impeller of packer machine 66L-PM1
in terms of the production process.
3. The cause of dust build-up on the impeller of packer machine 66L-PM1
in terms of the hydraulic.

1.4 The Purpose of Making Case Study

1.4.1 General Purpose
As one of the requirements to complete the Case
Study course Semester IV Diploma III Program Department
of Mechanical Engineering Study Program Cement
Industrial Engineering Jakarta State Polytechnic.
1.4.2 Special Purpose
From the problems obtained during the data
collection process, the case study aims to:
1. Determine the root cause of the Packer Machine
Jammed on the 66L-PM1.
2. Provide improvement ideas, analysis and
solutions as an improvement on the 66L-PM1
packer machine.
3. Optimized the performance of the 66L-PM1
1.5 The Benefits of Writing a Case Study
1.5.1 For students

3
 a. Become a place for students and students to deepen their
knowledge about the maintenance of a Packer machine.
b. Creating a sense of responsibility for students and students to be
more concerned about the maintenance and damage to each
equipment which greatly affects the cement production capacity at
PT Solusi Bangun Indonesia Tbk.
1.5.2 For Factory
a. Streamlining the factory production process.
b. Reducing the potential for unscheduled repairs
c. Prevent obstacles or disturbances that cause the packer machine to
stop.
1.6 Writing System[2]
CHAPTER I INTRODUCTION
Discusses the background, objectives, benefits, systematics, and
research locations.
CHAPTER II LITERATURE REVIEW
Discusses the theory that supports the equipment (packer machine)
discussed.
CHAPTER III RESEARCH METHODOLOGY
Discusses the workflow diagram of the task, explanation of work
steps, and problem solving methods to be worked on.
CHAPTER IV DISCUSSION
Discusses the specifications of the equipment (packer machine) used
as the object of research.
CHAPTER IV CONCLUSIONS AND SUGGESTIONS
Discussing conclusions and suggestions from the author for further
research progress.
BIBLIOGRAPHY
ATTACHMENT

4
1.7 Research Location
The location of this research was conducted at PT Solusi Bangun
Indonesia palnt Cilacap which is more precisely in the Packhouse Area.

Picture 1.7 Cement Production Flowsheet 1

5
 CHAPTER II
LITERATURE REVIEW
2.1. Cement Packing System PT Solusi Bangun Indonesia Tbk

In maintaining the quality of cement in its marketing process, PT Solusi

Bangun Indonesia uses a packaging system using cement bags. The packaging
system or packaging has an understanding as a coordinated system to prepare
goods to be ready to be transported, distributed, stored, sold, and also used by
consumers[3].
PT Solusi Bangun Indonesia Tbk uses machine assistance in the process
of packing cement products into cement bags. The former cement bags were
generally made of multi-layer kraft paper (up to 5 layers). Now, cement bags are
reinforced using PP woven fabric to reduce paper usage to only 1 layer of kraft
paper laminated with PP woven fabric[4]. The bag is also equipped with a valve
neck for use in rotary packing which most cement manufacturers use to
maximize filling capacity. This type of bag is a favorite of cement bag
manufacturers in Indonesia because it is resistant to weather humidity.
2.2. Cement PT Solusi Bangun Indonesia Tbk
Cement is a hydraulic adhesive for building materials when mixed with
water. Based on the application[1], cement is divided into several types, namely:
2.2.1 Portland Cement Type I (Ordinary Portland Cement)
This type of cement is most needed by the wider
community because there are no special requirements for
its use.
2.2.2 Portland cement type II (Moderate Sulfat Resistance)
This type of cement is cement with moderate hydration
heat or below type I portland cement and is resistant to
sulfate. This cement is suitable for high temperature areas
and in drainage structures.
2.2.3 Portland cement type III (High Early Strength Portland
Cement)
This type of cement is usually used in areas with low
temperatures or cold winters.

6
 2.2.4 Portland cemenr type IV (Low Heat Of Hydration)
This cement is suitable for areas with hot temperatures.
2.2.5 Portland cemenr type V (Sulfat Resistance Cement)
This type of cement is suitable for areas that require high
sulfate resistance.

PT Solusi Bangun Indonesia Tbk produces Portland Composite Cement

(PCC) type cement where the cement is produced for building, roads, paving
blocks, hollow bricks.[1] PCC is a hydraulic binder resulting from grinding
together portland cement slag and gypsum with one or more inorganic materials.
The inorganic materials include blast furnace slag, pozzolan, silicate
compounds, limestone, with a total inorganic content of 6%-35% of the mass of
composite portland cement. In the SBI factory that produces PCC, in the process
clinker and gypsum are added with mineral ingredients (fillers) with a content of
<35%.

2.3. Packer Machine

Picture 2.2 Packer Machine 1

In a factory that produces cement, it definitely requires an equipment that

functions as a cement filler into cement bags, as shown in Figure 2.2.
The packer machine is a cement filling machine into a cement bag with
a simple principle, where the operator inputs data on the amount of cement
according to the cement order and determines the working speed of the machine
on the packer machine monitor.
The types of Packer machines:

7
2.3.1 Stationary Packer Machine (In Line Packer Machine)
Stationary Packer Machine (in line packer) is a type of
packer that does not move (static). This packer consists of 4 tubes
in line with a capacity of 40 tph (800 bags/hour). The working
principle of the in line packer is that the impeller motor is started,
the bag is inserted into the filling funnel above the saddle. The
limit switch is depressed and sends a command signal to
withdraw when the bag is filled with cement with the appropriate
weight, the bag stool drops, the hole closes and the bag falls onto
the belt. The type of mechanical and electrical work is almost the
same, only distinguished by the filling opening on the electronic
type driven by a three position cylinder.
The core components of the Stationary Packer Machine
(in line) are:
1. Impeller box, consisting of a shaft impeller blade
whell and impeller blade.
2. Filling tube, consisting of a bag holder and a limit
switch, serves to fill cement into the bag.
3. Saddle bag or seat bag, consisting of a saddle.
4. Spring dan bag stool, for support.
5. Ratchet magnet complete (cylinder magnet),
consisting of a cool magnet cylinder and a ratchet
hook, this function is to open the ratchet hook.
6. Oil brake consists of a strip of bow, this strip of
claw functions as a damper so that the scale does
not experience shock when filling cement. For the
electronic type, the mechanics are almost the
same, they don't use a comparison weight because
they use load cells and pneumatic devices.

8
2.3.2 Rotary Packer Machine

Picture 2.3 Rotary Packer Machine 1

Rotary Packer Machine is a type of packer that rotates, for

example consisting of 6-8 tubes with a capacity of 95-120 TPH (1900-
2400 bags/hour) [5].
The working principle of the rotary packer is that around it there
is a spout to fill cement into the funnel. After the bag hole is entered, the
spout that enters manually touches the stick limit switch, the bag holder
clamps the bag, the slide plate opens and is driven by a three position
cylinder. The discharge weighing cylinder pressurizing cylinder runs
until it is fully charged, discharges to the discharge belt conveyor[5].
Rotary Packer Machine core components:
1. Rotary drive serves to rotate the packer at a speed that can be
changed as needed.
2. Material feed, rotary packer controlled by level control on
hopper packer.
3. Filling station, each has a driving machine to rotate the
impeller blade pushing cement.
4. Bag stoll, where the cement bag rests on the saddle that will
connect with the weighing tool.

9
 5. Pneumatic cylinder, moves on the orders of the manual valve
for the mechanical type and for the electronic type on the
command of the solenoid valve.

2.4. Packer Machine in PT Solusi Bangun Indonesia Tbk

PT Solusi Bangun Indonesia Tbk uses an equipment packer machine

with a rotary packer type of 8 packer machines. Each packer machine has 8
spouts. With a cement storage capacity of up to 40kg/bag and 50kg/bag. With
this capacity, the packer machine must supply cement and check its capacity
with a scale at each spout. This scale is coordinated by CCR according to market
demand so that it can detect the weight of cement in each bag and will be read
on each spout monitor.

At PT Solusi Bangun Indonesia Tbk, the packer machine has a HAC code
(Holcim Asset Code) 66F-PM1 to 66M-PM 1 which has different characteristics.
There are 3 types of packer machines at this cement factory. First, packer
machines that already use a pneumatic working system for each spout and
already use a motor as the driving medium, are the 66F-PM1, 66G-PM1, and
66H-PM1. Second, packer machines that use pneumatics for each spout and
blower for the driving medium are available in the 66L-PM1 and 66M-PM1.
Third, packer machines that still use a manual working system consisting of a
blower and one pneumatic for 8 spouts are available in the 66I-PM1, 66J-PM1,
and 66K-PM1.

One of the packer machines that will be discussed thoroughly is the 66L-
PM1 packer machine. 66L-PM1 is a ventomatic packer machine with a rotary
packer machine mod type. Ge “Plus”.COS is one of the manually operated
security devices and serves to disable / stop the Apron Conveyor in case of
danger.

10
2.5. Packer Machine Mod. Ge “Plus”

Picture 2.5 Packer Machine mod.Ge “Plus” 1

Packer machine mod. Ge “Plus” is a machine manufactured for

filling with cement (or similar products) paper bags with glued valves or sewn
bags. This machine allows configurations with a minimum of 8 spouts and
achieves a production capacity per spout of 300 bags/hour with 50 kg bags or
330 to 360 bags/hour with 25 kg bags.
2.6. Main Characteristics of Packer Machine 66L-PM1

The main characteristics of the packer machine mod. Ge "Plus" include:

2.6.1 Clockwise rotation or counterclockwise rotation hour hand,

which can be preset at the level design;
2.6.2 Recording the relative position of the spout, to perform the
sequence charging operation;
2.6.3 Control of single spout filling operation via Ventodigit operator
panel mounted on each spout;
2.6.4 Exchange of data between weighing system and panels operator
of each spout;

11
2.6.5 Synchronization of machine functions with additional
components (scales, remote control devices, surveillance
operations and monitoring, other packing lines and etc);
2.6.6 Configuration for automatic adjustment (option) of the bag-
holding seat so to adapt it to various the capacity of the bag
used.
2.7. Key Components of Packer Machine 66L-PM1

Picture 2.7 Key Components of Packer Machine 66L-PM1

2.7.1 Body machine

The body of the machine consists of a center shaft

controlled by a gear motor (Pos.1 Figure 2.7) and a support on a
proper support beam (Pos.2 Figure 2.7).

2.7.2 Electric Collector

Electric collector that supplies power to all electrical
components of the packer (Pos.3 Figure 2.7). Through this
element power is transmitted to all components of the Packer by
exchanging electrical energy between fixed points (feeding
brushes) and mobile points (rotating slip rings). The electric
collector is protected by a sheath, inside the fixed brush holder
(Pos.1 Figure 2.7.2) is mounted on the frame (Pos.2 Figure 2.7.2)

12
 and receives the voltage from Figure 2.7.2) mounted on the shaft
packer (Pos.4 Figure 2.7.2).

Picture 2.7.2 Electric Collector 1

2.7.3 Magic Box Group (card/encoder)

Magic Box Group which detects the angle of the packing
position and sets the intervention time for its application, bag
filling and discharge (Pos.4 Figure 2.7). This element records
each angular position of the packer to decide on different device
timing interventions (placing, filling, weighing and bag
evacuation). Each angular position is carried out by an encoder
(Pos.2 Figure 2.7.1) mounted on the rotating shaft of the machine
by means of a belt (Pos.3 Figure 2.7.1) and an optical jumper
(Pos.4 Figure 2.7.1) which transfers relative data from the
position which will be read by the Ventodigit panel operator.

Picture 2.7.3 Mechanic Magix Box 1

2.7.4 Rotation reduction gear

Gear that transmits rotation from the gearmotor to the
packer shaft (Post.5 Figure 2.7). This unit is mounted on the

13
 frame of the engine and transmits rotation between the gear motor
(Post.1 Figure 2.7.4) and the packing shaft (Pos.2 Figure 2.7.4).
The rotational movement is carried out by the pinion (Post.3
Figure 2.7.4) - the fifth wheel (Post.4 Figure 2.7.4) of the
transmission is in a closed housing (Post.5 Figure 2.7.4) filled
with oil.

Picture 2.7.4 Rotation Reduction Gear 1

2.7.5 Cylindrical Tank

Tanks containing cement products to be packaged (Post.6
Figure 2.7). The tank stores cement products and distributes
cement products evenly to the spout packer machine. The unit
consists of a metal frame with a cylindrical shape (Post.1 Figure
2.7.5) and a cover (Post.2 Figure 2.7.5). During the operation of
the machine, the tank rotates alternately, distributing the product
to the spout packer, the filling of the cement product is carried
out by the cell feeder through the slit (Pos.3 Figure 2.7.5) made
in the cover. When the tank rotates, the cover is in a fixed
position.

14
 Picture 2.7.5 Cylindrical Tank

2.7.6 Level Indicator

A level indicator (Post.7 Figure 2.7) is installed in the tank
which gives a signal about the cement product in it. There are 3
levels, namely high level, low level, and normal level. A level
indicator is placed in the tank (Post.1 Figure 2.7.6) and it is this
element that determines the amount of product on it. The level
indicator in the form of a vertical bar (Post.2 Figure 2.7.6)
indicates the cement product inside via the proximity
microswitch (Post.3 Figure 2.7.6). There are 3 levels, namely
high level, low level, and normal level.

Picture 2.7.6 Level Indicator 1

2.7.7 Cell feeder

The part that fills the cylindrical packaging tank with the
cement product to be packaged (Post.8 Figure 2.7). The feeder
feeds the packer tank (Post.1 Figure 2.7.7) through the gap made
in the cover (Post.2 Figure 2.7.7). Automatically, the feeder starts
when the level indicator (Pos.3 Figure 2.7.7) is at a low level,
which indicates a shortage of cement products in the tank. The
feeder consists of a gear motor (Pos.4 Figure 2.7.7) which
converts cells (Pos.5 Figure 2.7.7) via chain gearing. From the

15
 cell, the cement product flows from the upper hopper to the
packer tank.

Picture 2.7.7 Cell Feeder 1

2.7.8 Throttle valve

This valve allows the passage of cement product which
will flow from the feed hopper to the packer tank (Post.1 Figure
2.7.8). This element consists of a disk (Pos.2 Figure 2.7.8)
actuated by a pneumatic actuator (Pos.3 Figure 2.7.8), which
allows opening or closing of the valve.

Picture 2.7.8 Throttle Valve 1

2.7.9 Setting devices group

Setting devices group, which is installed between the
pump group and bag holder, functions to regulate the flow of
cement products from the tank to the nozzle packer. The setting
devices group is able to adjust the product flow from the turbine
(Pos.1 Figure 2.7.9) to the nozzle packer (Pos.2 Figure 2.7.9)
through the holes (Pos.3 Figure 2.7.9). This unit consists of a
plate (Post.4 Figure 2.7.9) and a counterplate (Post.5 Figure
2.7.9). Between them was installed the guillotine (Post.6 Figure
2.7.9). The movement of the guillotine is ensured by two

16
pneumatic actuators (Post.7 Figure 2.7.9). Its position determines
the opening of the hole through which the product flows.

Picture 2.7.9 Setting Devices Group 1

17
2.7.10 Pump group

The pump is mounted behind the bag holder, which

carries the cement product from the tank to the nozzle packer.
With this, the cement product is carried from the tank to the
nozzle packer (Post.1 Figure 2.7.10).

The rotational motion of both is provided by the motor.

The pump is positioned behind the bag holder, and allows the
cement product to be pushed by the turbine up to the spout; a
regulating device (Post.5 Figure 2.7.10) placed between the pump
and the spout, controls the quantity of cement product to be filled
into the bag, intercepting the product flow.

Picture 2.7.10 Pump Group 1

2.7.11 Bag Holder

The part that supports the bag during the filling cycle
(Post.10 Figure 2.7). The unit consists of an isostatic member
which is connected to the fixed structure by means of two carriage
springs (Post.1 Figure 2.7.12.1) at the bottom, while at the top it
is connected by a loading cell (Pos.2 Figure 2.7.12.1). This type
of connection allows the loading cell to detect the weight of the
product in the bag. The pneumatic actuator rod (Post.3 Figure
2.7.12.1) penetrates into the nozzle orifice when the bag is not
applied. If a bag is applied, the actuator rod locks it in the nozzle;
now the microswitch is activated, detects the position of the rod
and determines the presence of the bag.

18
 During filling, the bag is placed on the seat (Pos.1 Figure
2.7.12.2) which can be adjusted according to the size of the bag.
To fit a seat with various bag heights, the seat can be configured
in the following versions:
• Manual adjustment: seat position can be adjusted
manually (Figure 2.7.12.2).
• Pneumatic adjustment (Pos.3 Gambar 2.7.12.2):
the seat position can be adjusted on the operator
panel using two pneumatic actuators (Pos.5 Figure
2.7.12.2), by lifting or lowering the seat according
to the bag size.
• Automatic adjustment (Pos.4 Gambar 2.7.12.2)
with asynchronous motor: seat position can be
adjusted on the operator panel using a motor
(Post.6 Figure 2.7.12.2), which lifts or lowers the
seat according to bag size.

At the end of the filling cycle, the pneumatic

actuator (ejector - Pos.3 Figure 2.7.12.2) lowers the bag
and throws it onto the belt conveyor.

Picture 2.7.12.1 Bag Holder Unit 1

19
 Picture 2.7.12.2 Charging Cycle in Bag 1

2.7.12 Lower Support

The part that allows rotation of the packing. The lower
support is located at the base of the center of the shaft to allow
rotation of the engine, in addition it is connected to the
compressed air supply for the pneumatic device via a rotary
clutch (Post.1 Figure 2.7.13).

Picture 2.7.13 Lower Support 1

20
2.7.13 Control Group
Functions for each spout, containing electrical, pneumatic
and electronic devices to control the spout (Pos.9 Figure 2.7). The
GE Packer is equipped with a preassembled control group
mounted on the tank by spouts.
The control group consist of:
• Electric board (Post.1 Figure 2.7.14) at the top;
• Complete pneumatic control unit with connection
(Pos.2 Figure 2.7.14) in the middle;
• Electronic control unit (Post.3 Figure 2.7.14) at the
bottom.

Picture 2.7.14 Control Group 1

21
 2.7.14 Rubber Coupling
In some situations it is possible to attach the nozzle to the
bag holder unit (Post.1 Figure 2.7.15) with a rubber coupling,
which helps reduce product leakage during bag filling. After the
bag is installed, the clutch (Post.2 Figure 2.7.15) expands until it
is fully attached to the bag valve.

Picture 2.7.15 Charging Spout 1

2.8. Safety Improvement

Picture 2.8 Safety Improvement 66L-PM1 1

2.8.1 Safety barrier (Pos.1 Figure 2.8)

Protects moving parts and limits those areas where dust
comes in to make the dedusting machine more efficient. This unit
is expected to be able to provide access to a machine equipped
with a key for maintenance operations or to recover bags that are
not placed on the spout. To open the door it is necessary to extract
the key from the operator panel which disconnects the power
supply and allows it to operate safely.
2.8.2 Footboard

22
 This section is placed in the safety barrier opening (Pos.2
Figure 2.8) to obtain maximum operator safety when there is
manual placement of the bag in the spout packer. If the operator
accidentally steps on the footboard while the machine is moving,
the power supply will be cut off immediately.
2.8.3 Rope (Post.3 Figure 2.8)
The part connected to the safety switch can be operated
along the entire perimeter of the packer, where if there is a rope,
the operator cuts off the machine supply power and stops any
movement.

2.9. 66L-PM1 Packer Machine Duty Cycle

Picture 2.9 Working Cycle 66L-PM1 1

The packer work cycle begins with the installation of an empty bag
on the engine nozzle via the bag applicator system or manually. The static
microswitch detects the presence of an empty bag in the nozzle, and the
panel operator performs an autotaring operation to initiate the filling cycle.
Fill cycles are managed by the Ventodigit panel operator, who directly reads
the weights from the loading cell, encoder, and factory status (engine
running, evacuation belt running, etc.) via input from the card in the electric
cubicle.

23
 The bag holding unit (Pos.1 Figure 2.9) supports the bag during the
filling cycle, and determines the weight of the cement product in the bag via
the loading cell. The top of the packer is connected to a hopper (Post.2
Figure 2.9) whose function is to accommodate and feed cement products;
under the hopper is mounted a throttle valve (Post.3 Figure 2.9), which
allows the passage of product to the feeder (Post.4 Figure 2.9). The feeder
transfers the product and distributes it into the tank (Post.5 Figure 2.9).

The product is transported from the tank to the nozzle packer via a
pump. Setting devices cut off the flow of cement product, fully opening at
the beginning of the filling cycle, while partially closing towards the end,
and closing completely when the preset weight is reached. Finally the filled
bags are in the evacuation route (Post.6 Figure 2.9) to be carried by the belt
conveyor (Pos.7 Figure 2.9).Spesifikasi Khusus Packer Machine 66L-PM1.

2.10. Special Specifications of Packer Machine 66L-PM1

2.10.1 Overall Dimension 66L-PM1

Picture 2.10 Overall Dimension 66L-PM1

24
The production shown below relates to the 66L-PM1 . packer
configuration.

Table 2.10.1 Configuration 66L-PM1 1

40 kg 50 kg

Dimension (mm) 450x300 650x420

Paper Type Valve Glued Valve Glued
Paper Material Paper(plastic,raffia) Paper(plastic,raffia)
Table 2.10.2 Compressed air 66L-PM1 1

Pressure 6 bar
Filter 25 micron
Dew point 5°C
Maximum oil concentration 0,05 mg/m3
Consumption 40 Nm3/h
Packer GEO/GEV 6,5 Nm3 /hr
Table 2.10.3 Capacity 66L-PM1 1

40 kg 50 kg

Capacity (bags/hour per spout) 360 300

Table 2.10.4 Working Temperatures 66L-PM1

Maks. Relative humidity allowed 80%

Minimum allowable ambient temperature -20°C

(stocking)
Max allowable ambient temperature (stocking) +50 °C
Minimum allowable ambient temperature -10 °C (**)
(operating)

25
 Max. allowable ambient temperature +40°C
(operating)
Max. allowable production time (no breaks) 23,5 jam
Table 2.10.5 Dynamic Load 66L-PM1 1

Engine dynamic load 225 kN Beban dinamis m

2.10.2 Special Spesification 66L-PM1

Table2.10.6 Spesifikasi Khusus 66L-PM1 1

CPU Microcontroller Am188ES (compatible with

80C188), clock 40 MHz

MEMORY base for EPROM 128/512 kbyte, base for static

RAM 128/512 Kbyte supported by buffer
batteries, base for
RAM/EPROM/EPROM/FLASH EPROM
128/512 Kbyte supported by buffer batteries.
Totalling a maximum of 1Mbytes.
INTERFACE FULL CAN 2.0A and B
RS232 Serial Interface (Service ñ Connection <
3 mt.)
DISPLAY 2" graphic LCD, FSTN B/W 128x64, LED
backlight
KEYBOARD with 16 mechanical keys with polyester
covering, total stroke 0.3 mm, life 5x106
operations longer
Machine status reported by 22 LEDs

16 optoisolated digital inputs

16 optoisolated digital outputs: pnp 24V 0.5A

26
1 output 0 ñ 10 V analog

1 input for load cell: 350.1000 ohm

Watch dog

POWER SUPPLY 24 Vdc +-20% 1A max

OPERATING 0-50 °C
TEMPERATURE
HUMIDITY up to 85% (without condensation)
STANDARD Height 243 mm,
DIMENSIONS Width 128 mm,
Depth 80 mm,
Weight 3.5 kg.
PROTECTION IP54
CLASS
TECHNICAL Operating voltage
SPECIFICATIONS 15...30Vdc
Maximum absorbed current 1
A
Over-voltage protection Si
Polarity inversion protection Si

CONNECTION XP5.1 +24Vdc 1Amax XP5.2 GND XP5.3 PE

METHOD ground

27
2.11. Pneumatic System 66L-PM1

Picture 2.11.1 Connection Pneumatic 66L-PM1

The control group installed in the tank by the spout consists of the
following:

• electrical board at the top (Post.1 Figure 2.13.1);

• pneumatic control unit in the center (Post.2 Figure 2.13.1);
• electronic control unit at the bottom (Post.3 Figure 2.13.1);
• Support with pneumatic connections (Post.4 Figure 2.13.1) for
flexible pipes of various diameters.

The filling spout is equipped with a pneumatic system that connects the
actuator placed on the weighing frame to the fixed part of the spout.

The pneumatic connection is obtained by inserting the pipes into the

fittings installed on the filling spouts (Pos.1 Fig.4.25), making them pass through
the appropriate holes in the tank (Pos.2 Fig.4.25) and finally channeling them
into the pipes (Pos.3 Fig. 4.25). In this way, pneumatic joint joints (Pos.4

28
Fig.4.25) are obtained, marked with the same number. To obtain such a
connection flexible pipes are used, inserting their ends into the fittings.

Picture 2.11.2 Pneumatic System 66L-PM1 1

The filter reduction unit treats the air in the packer machine. The pressure
of the supplied air must be more than 6 bar, if it is less it will stop all machine
functions.

Picture 2.11.3 Pneumatic Connection 66L-PM1

29
 Picture 2.11.4 Pneumatic Diagram 66L-PM1

A - Fluidification

B - Setting device group

C - Bag Lock

D - Bag Ejector

E - Throttle valve

F - Silo fluidification

2.12. Bearing 66L-PM1

Bearing is a machine element that serves to limit the relative motion

between two or more machine components so that they always move in the
desired direction. Bearings are an important component in various engine
designs involving shafts with casings or stationary parts, such as electric motors,
combustion engines, pumps, wheels, and so on. Bearings are the meeting point
between the rotating machine parts and the stationary parts. It is also in charge
of transmitting the load on the shaft to be forwarded to the side of the casing, or
vice versa. Each bearing has an optimal age limit that can be calculated. But in
reality, not all bearings are able to achieve optimal service life [7].

Bearing is a mechanical component of the engine that serves to reduce

friction between two moving engine components, support the rotational position

30
of engine components, and facilitate rotation on a rotating shaft against a fixed
component (silent).

The types of bearings in general, as follows:

2.12.1 Friction Bearing

This type of bearing is a bearing whose frictional plane
moves in a shifting manner and is in direct contact between the
bearing surface and the machine components it supports. As a
result, friction on the surface of this type of friction bearing is
very high.
This is because friction bearings do not have intermediate
components that rotate in them, but instead, friction bearings use
a thin layer of oil as an intermediary so that friction between
surfaces does not damage the bearing. The following are the types
of friction bearings available.
Plain bearings are bearings that have a flat surface in the
friction plane even though the bearing shape is curved like a semi-
circle. Bushing is a type of friction bearing with a circular shape
like a ring.
2.12.2 Anti-Friction Bearing
Anti-Friction Bearing is a bearing in which the friction plane
moves in a revolving manner, but the friction plane of the bearing surface
with the engine components that the bearing is not in direct contact with,
but there are other bearings that become rails / stands.
Anti-friction bearings are broadly divided into two types, namely
ball bearings and roller bearings.
Ball Bearing is a bearing that uses a steel ball that is placed
between the two rails which functions as a groove and the way the ball
rotates. Ball bearings are further divided into several types, namely:
• Single Flow Radial Ball Bearing
• Axial Thrust Ball Bearing
• Angular Contact Ball Bearing

31
 • Self-Aligning Ball Bearing
• Single Flow Radial Ball Bearing
• Axial Thrust Ball Bearing
• Angular Contact Ball Bearing
• Self Aligning Ball Bearing
Roller Bearing is a bearing that uses a steel roller (shaped like a
cylindrical tube) which is also placed between two bearings as a friction
plane. Roller bearings are divided into several types, namely:
• Cylindrical Roller Bearing
• Flexible Roller Bearing
• Needle Bearing
• Tapered Roller Bearing
• Spherical Roller Bearing
• Roller Thrust Bearing
The 66L-PM1 has bearings on the top and bottom with ball bearing
types.

32
 With the following specifications:

Picture 2.12.2 Ball Bearing 66L-PM1 1

Stable and with good spinning characteristics. The stainless steel

deep groove ball bearing SS-6214-2RS is a true all-rounder and, due to its
balanced properties, it is suitable for a variety of applications and is resistant
to corrosion. Main dimensions according to DIN 625-1.
Features:
• all components are made of stainless steel: the deep groove
ball bearing has therefore good corrosion resistance to mild
media (e.g fresh water) and is hygienic

33
 • light series with compact dimensions and low weight
• can carry relatively high radial loads despite low weight
• suitable for high radial loads and light axial loads in both
directions
• offers high running accuracy, quiet running and high speeds
• seal: contact lip seal on both sides made of rubber (2RS) for
high sealing effect
• If you need this bearing in RS design with only one seal and
one open side, you can simply remove one of the two seals:
to the instructions
• good fixed bearing property, but can also be used as a floating
bearing, each in both directions
• manufacturers of bearings, such as FAG, KOYO, NSK, SKF,
SNR, etc. assign different suffixes for their characteristics, for
better orientation take note of the comparison table of
bearings (see further information)
Table 2.12.2 Technical Data Top Bearing 66L-PM1

Diameter inside 70 mm
Diameter Outside 125 mm
Width 24 mm
Tolerance for diameter 0 mm
inside -0,015 mm
Tolerance for diameter 0 mm
outside -0,018 mm
Tolerance for width 0 mm
-0,15 mm
Rows of balls Single row
Seal 2RS
Internal Clearance CN (standard)
Flange No
Slot & Snap Ring Nein
Ring material Edelstahl
Rolling element material Stainless steel
Cage material Stainless steel
Full Complement Ball set No
Magnetic Yes
Type of lubrication Gefettet
Lifetime lubricated Yes
Product weight 1,0700 kg

34
Table 2.12.2 Manual Book Bearing 1

35
Buttom Bearing 66L-PM1

Picture 12.2.2 Buttom Bearing 66L-PM 1

The self-aligning ball bearing was invented by SKF. It has two rows of balls and
a common sphered raceway in the outer ring. The bearing is consequently self-
aligning and insensitive to angular misalignments of the shaft relative to the
housing.

36
The design of self-aligning ball bearings is such that angular misalignment
between the outer and the inner rings can be accommodated without any negative
effect on bearing performance.

Dengan spesifikasi:

Table 2.12.2 Technical Data 1

Diameter inside 80 mm
Diameter Outside 170 mm
Width 39 mm
Basic load ratings
Dynamic 88,4 kN
Static 33,5 kN
Fatigue load limit 1,50 kN
Speed ratings
Reference speed 7 500 r/min
Limiting speed 5 300 r/min
Mass 4,20 kg
Tolerance for diameter 0 mm
inside -0,015 mm
Tolerance for diameter 0 mm
outside -0,018 mm
Tolerance for width 0 mm
-0,15 mm
Rows of balls Single row
Seal 2RS
Internal Clearance CN (standard)
Flange No
Slot & Snap Ring Nein
Ring material Edelstahl
Rolling element material Stainless steel
Cage material Stainless steel
Full Complement Ball set No

37
 Magnetic Yes
Type of lubrication Grease
Lifetime lubricated Yes

2.13. Lubrication System 66L-PM1

Picture 2.7.11 Grease System 1

Based on its understanding, lubrication is a lubrication or cooling

system that is carried out on the engine and the components in it to keep
it from experiencing friction and wear so that it is always in prime
condition. In various types of machinery and equipment that are moving,
there will be friction between metals[7].

Lubricants (oils) are also distinguished based on their application,

namely automotive applications and industrial applications. Because
automotive applications operate at high temperatures (charter) with viscosity
values referred to at 100 oC and further standardized by SAE but industrial
applications operating at normal temperatures (sump tanks) with viscosity
values referenced at 40 oC and further standardized by ISO.

38
 The life of the lubricant is highly dependent on the workload, the
expertise of the technician, the environmental conditions and the completeness
of the supporting facilities and infrastructure, in addition to the quality of the
lubricant itself. We recommend that the age of the lubricant is not determined
based on operating time or distance traveled but based on the condition of the
lubricant itself by testing through a standardized lab.

Like oil lubricants, grease lubricants are also distinguished by their

application: Automotive which is further standardized by NLGI (LB, GC, GC-
LB) and Industry which is further standardized by ISO (ISO-L-X). In addition
to its application, grease is also differentiated based on its thickener, namely:
Lithium, Calcium, Aluminum, Bentonite, Polyurea, Lithium Complex, Calcium
Complex, Aluminum Complex, etc.

The liquid is named lubricant while the system is lubrication.

In general, bearing lubrication systems are divided into three

types, namely:

2.13.1 Grease Lubrication

Grease is a lubricant with a semi-solid structure. Grease

is a base oil mixed with an additive (tigener). Grease is made from
mineral or vegetable oil mixed with a thickening agent such as
soap. Sometimes additives such as PTFE, graphite, and
molybdenum desulphite are added to improve their lubricating
properties. Grease is used in bearing mechanisms that require
little lubrication, where there is no need to use oil as a lubricant.
Grease also serves to prevent the entry of dirt into the bearing.

39
 2.13.2 Oil Lubrication
Bearing lubrication that uses oil, is needed in machines
with high workloads. The oil lubrication system also functions to
absorb heat that arises in the bearing area due to high workloads.
In addition, bearing oil lubrication is also used in machines that
operate at high temperatures, such as the feed water pump in the
water-steam cycle, which functions to pump high-temperature
water from the tank to the boiler.
2.13.3 Dry Lubrication
This third lubrication system does not involve liquid-based
lubricants such as grease and oil, this system uses solid materials
that are attached directly to the friction surface.

The 66L-PM1 packer machine requires a lubrication system as a

system to maintain and extend the life time of the equipment. On the 66L-
PM1 packer machine there is a lubrication process, including:

1. Top bearing
Lubrication system on top bearing 66L-PM1 by
providing mobile grease XH4-462 ISO VG 460.
2. Buttom bearing
Lubrication system on buttom bearing 66L-PM1 by
providing mobile grease XH4-462 ISO VG 460
3. Motor
4. Reducer motor

The process of giving is in the scheme below:

40
Specification:

By using a cubing pipe with a diameter of 10 mm along 4 meters. This

pipe is able to withstand heat or high temperatures up to 100 degrees
Celsius.

The density of grease is 700-950kg/m3 or 0.7-0.95 gram/cm3.

Buttom bearings are medium-sized bearings, so the grease on the bottom

bearings is about 20 grams every 2 weeks. Where in one stroke is able to
provide grease of 6 grams / minute. Therefore, grease should be given for
20/6 or 3 minutes every day. In other words, 1 kg intervals once a week.

System for manually lubricating group pumps. The pump group is

equipped with an automatic lubrication system. Its function is to allow
the passage of grease in the chamber (Post.2 Figure 2.7.11) through the
hole (Post.1 Figure 2.7.11), providing a seal and prolonging the life of
the pump group. Greasing system or lubrication system consists of a
grease tank (Post.3 Figure 2.7.11), pump (Post.4 Figure 2.7.11) and
feeder (Post.5 Figure 2.7.11). which distributes grease to all turbine
packers.

41
2.14. Maintenance 66L-PM1
2.14.1 Definition of Maintenance
Many affect the level of consumer confidence in
producers or companies, one of which is how the level of service
provided by the company affects consumer satisfaction[6]. This
is the responsibility of the production department. The factor that
causes this is the non-smooth production process. The causes of
the non-smoothness of this production process include the
damage experienced by the machine when the production process
is running. To prevent this, it is necessary to take maintenance
actions on the machine.
All goods made by humans have a service life and will
eventually experience damage. The service life of goods can be
extended by carrying out an activity known as maintenance
(Yudhi, 2008).
Maintenance is the main supporting activity that aims to
ensure the functional continuity of a production system
(equipment) so that when needed it can be used in accordance
with the expected conditions. This can be achieved, among
others, by planning and scheduling maintenance actions while
still paying attention to their supporting functions and by paying
attention to their supporting functions and by taking into account
the minimum 8 cost criteria to anticipate the level of damage and
prevent interruptions in production activities. Maintenance is an
activity to maintain or maintain the machine/equipment in the
best condition so that it can be used to carry out production
according to the plan.
Maintenance of a tool is very necessary to protect the tool
from physical damage to the tool and damage to the function of
the tool. The Preventive Maintenance Department is responsible
for maintaining equipment in the raw mill area of PT. Solutions
to Build Indonesia Cilacap. Maintenance activities of all

42
 equipment must be scheduled by the Packhouse Maintenance
Department and the preventive maintenance department.
2.14.2 Maintenance Purpose
a. The machine can produce output according to the planned needs.
b. The quality of the products produced by the machine can be maintained
and in accordance with expectations.
c. Prevents severe damage that requires higher repair costs.
d. To ensure work safety using the machine in question.
e. Maximum machine availability (reduced downtime).
f. Can extend the life of the machine or work equipment.
2.14.3 Maintenance Classification on 66L-PM1
Maintenance is needed to keep the equipment from damage
and can make the equipment run properly during operation. There
are several types of maintenance on the 66L-PM1 packer
machine:
a. Periodical Maintenance 66L-PM1
Periodical maintenance consists of preventive and
predictive maintenance, which is carried out regularly, daily,
weekly, monthly and yearly for the mechanical and electrical
side. This is done to check and find out some potential
problems that occur, as well as estimate some potential damage.
If there are some findings (eg: damaged parts), we can repair or
replace them with new ones. Good preventive maintenance can
minimize equipment downtime.

43
 b. Shutdown Maintenance 66L-PM1
Shut Down Maintenance is a type of maintenance that is
scheduled to be carried out once in a period. At PT. Solusi
Bangun Indonesia Cilacap, Shut Down Maintenance is carried
out every three months which is called Short Shut Down.
The Preventive Maintenance Department has collected
notifications and compiled them into data. The data is a work
order by the planning team. Based on the job order, the
Preventive Maintenance and Mechanical Packhouse
Departments take follow-up actions. Items of maintenance
performed by the preventive maintenance department:
• Major Overhaul, full replacement of all parts of an
equipment and make modifications when
necessary, such as: replacement of chain link sets,
lamella sets, sprockets and bearings (head and
tail), and modification of chute/skirt.
• Short Shut Down (SSD), replacement of several
parts on an equipment based on critical conditions
based on the results of Preventive Maintenance
analysis and decisions, such as: replacement of
chainlink, lamella and body chute which only
suffered damage.

c. Breakdown Maintenance 66L-PM1

Break-Down Maintenance is a type of maintenance that is
carried out after an equipment has a problem. In Break Down
Maintenance, we repair and/or replace parts that experience
problems during operation.

44
 CHAPTER III
METHODOLOGY

3.1 Problem Resolution Method

Problem solving methods are useful for solving problems that have
been formulated and achieving predetermined goals with various stages of
research and also data sources.

This research begins with:

3.1.1 Problem Identification

In this method, observations are made by observing the Pack
House Area, especially the Packer Machine 66L-PM1 area. In
addition, we also identify cement production systems and processes
to determine the characteristics of the production process and the
equipment used.
3.1.2 Start
At this stage, we determine the title of several problems that
often occur and have a big impact on factory production.
3.1.3 Discuss Method
Discuss existing problems with related parties such as field
supervisors, finish mill patroller area employees, finish mill area
maintenance, pm inspector finish mill area and engineer finish mill
area to get an explanation. We also collect data on potential
problems that can arise, the effects of these potential problems and
their causes based on their actual occurrence. Activities to collect
data about the tool by means of observation, interviews, and
documentation.
3.1.4 Literature Study
Searching and collecting information about the working
system of tools, processes and layout designs related to the project
location from books, journals, specification data, vendors, internet,

45
 and manual books. This activity also conducts a review study of
relevant sources.
3.1.5 Analysis Method
After the literature study is completed, an analysis of the
quality aspects, safety aspects, as well as an analysis of the
benefits/benefits in terms of mechanics and production will be
obtained after our analysis is applied. Activities to analyze the data
that has been collected and find solutions to the root of the problem.
The analysis we use is Fishbone

The following is a Flowchart of the Case Study

implementation method:

Bagan 3 Diagram Alir Studi Kasus 1

46
 CHAPTER IV
DATA AND ANALYSIS

4.1 Main Problem Analysis of Broken Bearing on 66L-PM1

The main problem of an equipment we cannot directly determine

and make repairs without conducting an in-depth data analysis of the factors
behind the problem. The data is strong and can provide correlations or
instructions for conducting further analysis towards the root causes and
determining improvement efforts. The Packer Machine equipment is no
exception in the packhouse area. One of them is the 66L-PM1 packer
machine, where it is necessary to do an analysis of each stage behind the
problems that occur for further efforts, namely repairs. The problem that
occurs is that the 66L-PM1 packer machine has a uschedule breakdown due
to jammed, where the buttom bearing collapses. The stages in the analysis
of the main problems of the 66L-PM1 jammed packer machine:

4.1.1 Performa Packer Machine 66L-PM1

At the end of November 2021, the 66L-PM1
packer machine experienced an unscheduled
breakdown due to jammed in the packhouse area for
279.20 hours.
4.1.2 Loss Production due to Unschedule Breakdown
PT Solusi Bangun Indonesia Tbk experienced
a decrease in benefits or in other words experienced
a large loss as a result of an unscheduled breakdown
of one of the equipment in the packhouse area,
namely the 66L-PM1 packer machine.
The company's losses due to the jammed
66L-PM1 packer machine are as follows:

47
 The price of one cement Rp 46.900,00
bag "dynamix" per 40
kg
Feed rate packer 79,2 t/h
machine
1980 cement bag/h

Stop duration packer 12 days

machine 66L-PM1
279,20 hours

So the loss can be calculated as follows:

Loss/Decrease in Benefit experienced by the factory:
= 1980 cb/h x 279,20h x Rp 46.900,00/b

= Rp 25.927.070.400,00

Based on the table above, the loss caused by

the 66L-PM1 packer machine experienced an
unscheduled (jammed) breakdown of Rp.
25,927,070,400.00. The loss comes from Loss
production in accordance with the stop packer
machine 66L-PM1 caused by the collapse of the
buttom bearing.

48
4.2 Problem Finding Analysis

On November 19, 2021, PT Solusi Bangun Indonesia Tbk

experienced an unscheduled breakdown because the 66L-PM1 failed to
spin. There is a noise from the inside of the packer machine before the
packer machine stops. The cessation of one packer machine greatly affects
the cement packing process. One less power from the packer machine makes
the company delay in the marketing process and reduce the benefits or the
company's target is not met on time. This will greatly affect the quality of
the company and a very large loss is felt by the company.

The first check was carried out on the motor packer machine which
tripped suddenly. When the motor is removed from the packer machine and
a no-load test run is performed, the motor can still be run. This means that
the motor is not the main cause of the 66L-PM1 packer machine stopping.

Next, checks are made from the mechanical side, namely the bottom
and top bearings. In fact, both were broken with no more lubricant in each
ball bearing. After analysis, the grease pipe leading to the buttom bearing
had a leak so that the grease did not reach the 66L-PM1 buttom bearing.

4.3 Fishbone Diagram

49
 The following is the root cause analysis using the fishbone diagram
method:

50
51
4.4 Cause Discussion
Based on the fishbone diagram as shown above, we get the following
analysis:
4.5.1 Engine Factor
Based on the results of discussions with hydraulic
and lubrication employees, the lubrication process for the
66L-PM1 bottom bearing can be carried out without having
to stop the packer machine first. At the time of the incident,
it was found that the grease in the bottom bearing 66L-PM1
was empty or had no lubrication. This happens because the
regreasing process does not reach its destination, namely the
bottom bearing.
The process was hampered due to two things. First,
the grease pipe that delivers grease from the outside area to
the bottom bearing has a leak so that the grease spills out.

Gambar 4.5.1 Skema Jalur Pemberian Grease 1

Second, checking regreasing is difficult to know

because the bottom bearing area is very difficult to reach and
is in a confined space.
Then, as previously known that the packer machine
is overloaded due to lack of lubrication, this causes the
temperature on the buttom bearing to be high and hot. If this

52
 happens continuously, the seal on the bottom bearing will
expand and leak.
Based on the results of discussions with mechanical
employees, the 66L-PM1 packer machine indicated that
there was a problem when an abnormal sound was heard
from the bottom of the packer machine. The movement of
the packer machine also looks heavier because there is no
lubricant. As a result of the bearing continuously
experiencing direct friction with the shaft, between metal and
metal causes a squeaking sound and the bearing temperature
rises / heats so that the seal expands and leaks. Seal leaks
make it easier for dirt, dust, and fine metal to enter and mix
with the grease so that lumps hinder the movement of
bearings and shafts. Therefore, the 66L-PM1 packer
machine is unbalanced because the buttom bearing is no
longer centered. The 66L-PM1 packer machine works harder
because the load is bigger. This had an impact on the 66L-
PM1 buttom bearing which collapsed.
Buttom bearing 66L-PM1 moves as a pedestal or
shaft from the movement of the top bearing which is
connected by a 3 meter long shaft. Therefore, with the
damage that occurs to the bottom bearing which causes the
shaft to be out of balance, it affects the 66L-PM1 top bearing.
Top bearing 66L-PM1 is overloaded because the shaft load
is placed on the top bearing. The seal on the top bearing
expands so that dirt or fine dust enters the top bearing and
forms lumps that hinder the movement of the bearing.
4.5.2 Method Factor
Based on the results of discussions with packer
machine area employees, it is known that the buttom bearing
packer machine is located in a confined space or an area that

53
 is difficult to reach so that it can only be checked for grease
and other work on the buttom bearing only when it is stopped
running, where the packer machine is used very often or
almost never stop running. This causes a lack of inspection
on the 66L-PM1 buttom bearing because there is no safe,
easy, and practical check regreasing.
With the lack of inspection on the bottom bearing
grease given to the engine parts. We can only find out
the grease until it is filled from outside the machine.
In addition, the packer machine is one of the
equipment whose operations are heavy, where the use of the
packer machine depends on the amount of production needed
every day. Where the production of cement every day is
always increasing so that almost all packer machines work
for a long time and stop for a moment.
4.5.3 Environment Factor
Based on the results of discussions with production
employees, the cleaning process on the 66L-PM1 buttom
bearing can be carried out when there is work that requires
the packer machine to stop so that at the same time the
buttom bearing can also be checked and can be cleaned of
foreign material.
Due to the difficulty or lack of cleaning work in the
packer machine, especially in the bottom bearing area, it
causes a lot of fine dust and grams of metal to stick and mix
with leaking oil or grease. The mixture forms a lump which
causes blocking.

54
 If blocking occurs, the more it is allowed to cause
resistance to the engine speed so that the load on the engine
increases. This of course will trigger a large vibration that
requires a cleaning process at that time. Until now, there is
no routine schedule for the cleaning process or the cleaning
process is still minimal.
4.5.4 Material Factor
In the process of greasing the buttom bearing 66L-
PM1 using a 10mm cubing pipe. The pipe is located at the
bottom of the packer machine which is buried by hot material
so that the pipe is hot and expands. This pipe has the property
of rapidly expanding if it is at temperatures above 45 degrees
Celsius. Therefore, this pipe is then broken.

55
 CHAPTER V
CONCLUSION AND RECOMMENDATION

5.1 Conclusion
5.1.1 Root Cause Cause of Packer Machine jammed or
Breakdown Unschedule at 66L-PM1, namely:
a. Machine
- The bottom bearing is located in a confined space so it is difficult to check and
maintain. Buttom bearing packer machine is located in a confined space so
that it can only be checked for grease and other work on the bottom bearing
only when it is stopped running.
- The grease pipe is broken so that no grease enters the bottom bearing 66L-
PM1.
- Friction of the ball bearing without lubricant causes the bottom bearing 66L-
PM1 to be broken. The bottom bearing 66L-PM1 collapses because it is not
strong enough to withstand excessive loads which also means that the pedestal
is no longer in the center. As a result, the packer machine 66L-PM1 becomes
abnormal sound.
- The imbalance in the movement of the 66L-PM1 bottom bearing also affects
the 66L-PM1 top bearing. Buttom bearing that no longer has a center pedestal
causes the top bearing 66L-PM1 to be broken.
b. Metode
- Spare parts for the packer machine are not made in Indonesia, but abroad, so
it takes a lot of time and money if a problem occurs.
- The increasing demand for cement production every day makes it impossible
for the 66L-PM1 packer machine to have a long stop.
c. Environment
- Lack of inspection on the 66L-PM1 buttom bearing due to the absence of a
safe, easy, and practical check regreasing.

56
- There is no routine schedule for the cleaning process or the cleaning process
is still minimal so that the blocking material accumulates important parts in
the 66L-PM1 packer machine.
d. Material
- Pipa cubing tertimbun material panas sehingga temperature pipa cubing
meningkat dan mengalami pemuaian sampai dengan pipa tersebut broken.
1.1.2 Effect of Jammed or Unscheduled Breakdown on 66L-PM1
to the next Equipment performance.
Lack of full attention to a factory equipment can
result in fatal events that have a large risk of loss. The
reduction in equipment in a factory will greatly affect the
process and also the production produced by a factory.
Leakage in grease pipe in 66L-PM1 caused
regreasing failure which should be done every month.
Regreasing that has not reached the buttom bearing causes
the buttom bearing temperature to be high, the seal leaks, and
the oil mixes with foreign material and blocking occurs. Not
only that, another result is that the rotation is not in the center
and is not balanced, causing abnormal sounds and the motor
trips. The broken buttom bearing 66L-PM1 causes the
packer machine to experience jammed or unscheduled
breakdown which of course will have a major impact on the
cement production process at PT Solusi Bangun Indonesia
Tbk.
5.1.3. How to Optimize Packer Machine 66L-PM1
From our research and discussions with employees
and workers in the field, it is necessary to have a regreasing
pipeline that is safe, easy, and practical so that it is known
whether it has been fulfilled or not. Then we will suggest the
design of the regreasing process pipeline to be installed near

57
 the bottom bearing 66L-PM1. Later the pipe is expected to
optimize the performance of the 66L-PM1 bottom bearing.

5.2 Recommendation
5.2.1 Creating a Safety Working Procedure for Work Regreasing
on Buttom Bearing 66L-PM1
5.2.2 Creating a Safety Working Procedure for Work Correcting
greasing on Buttom Bearing 66L-PM1
5.2.3 Creating a Safety Working Procedure for Cleaning on
66L-PM1
5.2.4 Designing the Grease Entry Path to the Button Safe, Easy,
and Practical Bearings.
Then we will suggest a safe, easy and practical
regreasing pipeline design. This line will be installed in the
bottom bearing area of 66L-PM1. Later the pipeline is
expected to optimize the performance of the 66L-PM1
buttom bearing packer machine.
5.2.5 Replacing the grease conveying medium to the bottom
bearing 66L-PM1 by using hoses.
5.2.6 Creating an automatic greasing system, with add grease
hoses line to bottom bearing line packing machine 66L-
PM1.
5.2.7 Make a Preventive Maintenance Schedule for Each Packer
Special Machine 66L-PM1.
5.2.8 Expected to pay more attention to the
condition of the machine by estimating the time of machine
breakdown through calculation of operating life to
anticipate damage machine and can assign maintenance
steps machinery and replacement of engine components
before the occurrence engine damage.

58
5.2.9 Recording historical data on engine performance includes
work in Preventive Maintenance Department.
A historical record is a document that informs about all
the work that has been done on the equipment. So that all
maintenance data is entered and stored on historical record
cards. Recording of events under maintenance made in
accordance with the conditions and parts of the equipment.
5.2.10 Provide spare parts or spare parts for every equipment in
the PT Solusi Bangun factory Indonesia.

59
 BIBLIOGRAPHY

[1] PT. Solusi Bangun Indonesia, “Profil PT. Solusi Bangun Indonesia.” 2020,
[Online]. Available: https://solusibangunindonesia.com/.

[2] “FY GUIDE AND THESIS 2020 Rev.” ..

[3] F. I. Cahyani and S. M. Retnaningsih, "Analysis of Quality Control of the

Cement Bagging Process at PT Semen Indonesia (Persero) Tbk with a Six
Sigma Approach," Its Science And Art, vol. 4, pp. 254–259, 2015.

[4] H. Shim et al., Adv. Opt. Mater., vol. 10, no. 1, pp. 1–9, 2018

[5] Engel, Pap. Knowl. . Towar. a Media Hist. Doc., pp. 10–31, 2014.

[6] R. R. G. A. Siwabessy et al., "Analysis of Maintenance Activities on

Sludge Separator Machines To Optimize Critical Parts With Realibility
Centered Maintenance (Rcm) Approach," J. Ind. Res., vol. 14, no. 1, pp.
117–123, 2015.

[7] “BEARING.” .

[8] H. R. Purba, “Application of predictive maintenance using methods,” pp.

18–60, 2018.

9. Thursday, 07 July 2022 13:43- https://alppetro.co.id/id/faq

10. Sunday, 31 Juli 2022 09:21 https://www.kugellager-express.de/stainless-steel-
deep-groove-ball-bearing-ss-6214-2rs-70x125x24-mm

60
 PT Solusi Bangun Indonesia Tbk
Version : 1.0 Subject : 1/2
SOP Guide Effective date : -

Title : SOP for Regreasing Buttom Bearing Packer Machine 66L-PM1

STANDARD OPERATING PROCEDURE

OBJECTIVE: So that every mechanical and hydraulic officer can carry out the work of Regreasing
Packer Machine 66L-PM1 properly and correctly
SCOPE : 66L-PM1

DEFINITION : Greasing the Top and Buttom Bearing Packer Machine 66L-PM1

TITLE : Top Regreasing and Buttom Bearing Dept : Page : 1

AREA : Packhouse area Man power : 2 Number: Maker :
peoples
NO PART Time Job Description Picture
1. Preparati- 10 ❖ Prepare a manual/automatic
on minu- grease pump.
tes

Danger:
• Pinched
• Slips
• Danger of dust and fine
materials
• Electrocution

Prevention:
• Use proper personal
protective equipment such
as safety shoes

61
2. Implemen 10 ❖ Pump grease until it is filled to
tation minu- the capacity required by the
tes top/buttom bearing. (around 5-
7 times pump)
❖ Characteristics indicate that
when pressed, the pump is
already heavy.

Danger:
• Pinched
• Slips
• Danger of dust and fine
materials

Prevention:
• Use personal protective
equipment properly such as
safety shoes, safety helmets and
safety gloves.

TOOLS a. Automatic hydraulic pump

b. WD40
c. Majun
d. Flashlight
Total times 20 SAFETY
Minu-
tes

REVISION ➢ Use PPE such as safety helmet, APPROVED

DATE REV DE MGR gloves, goggles, safety shoes, DATE SI MGR
SC safety mask
➢ Make GWP, LST, JPT, closed
space work permits, hot work
permits.

62
 PT Solusi Bangun Indonesia Tbk
Version : 1.0 Page : 1 / 2
SOP Guide Effective Date : -

Title : SOP for Checking Grease on Buttom Bearing Packer Machine 66L-PM1

STANDARD OPERATING PROCEDURE

OBJECTIVE: So that every mechanical and hydraulic officer can carry out the work of Regreasing
Packer Machine 66L-PM1 properly and correctly
SCOPE : 66L-PM1

DEFINITION : Grease Check on Top and Buttom Bearing Packer Machine 66L-PM1

TITLE : Grease Check on Top and Buttom Bearing Dept : Page: 1

AREA : Packhouse area Man power : NO : Maker :

NO PART Time Job Description Picture

1. Do the 10mnt ❖ Coordination between
LOTO mechanics, patrollers,
procedure hydraulics, Elc shifts to carry
out LOTO procedures in LSS
(When
and Local Switches.
checking )
Danger:
• Electrocution
• Slip
Prevention:
• Use proper personal
protective equipment such
as safety shoes

63
2. Prepara- 1 ❖ Ensure that the packer
tion and hour machine no longer has residual
Imple- current.
mentation ❖ Ensure cleanliness in the
packer machine area before
opening the main hole packer
machine.
❖ Check from the beginning of
the grease entering until the
grease is in the bearing.
Danger:
• Pinched
• Confined Space

Prevention:
• Use personal protective
equipment properly such as
safety shoes, safety helmets and
safety gloves.

TOOLS a. Compressor
b. Majun
c. Flashlight

Total times 1 hour SAFETY

10
mnt

REVISION ➢ Use PPE such as safety helmet, APPROVED

date REV desc MGR gloves, goggles, safety shoes, date SI MGR
safety mask
➢ Make GWP, LST, JPT, closed
space work permits, hot work
permits.

64
 PT Solusi Bangun Indonesia Tbk
Version : 1.0 Page : 1 / 2
SOP Guide Effective Date : -

Title : SOP for Cleaning area Packer Machine 66L-PM1

STANDARD OPERATING PROCEDURE

OBJECTIVE: So that every mechanical and hydraulic officer can carry out the work of Regreasing
Packer Machine 66L-PM1 properly and correctly

SCOPE : 66L-PM1

DEFINITION : Cleaning area Packer Machine 66L-PM1

TITLE : Cleaning area Packer Machine 66L-PM1 Dept : Page: 1

AREA : Packhouse area Man power : NO : Maker :

NO PART Time Job Description Picture

1. Do the 10mnt ❖ Coordination between
LOTO mechanics, patrollers,
procedur hydraulics, Elc shifts to carry
out LOTO procedures in LSS
e
and Local Switches.
(If done
Danger:
in a
• Electrocution
confined
• Slip
space)
Pencega Prevention:
• Use proper personal
protective equipment such
as safety shoes.

65
2. Prepara- 1,5 ❖ Ensure that the packer
tion and hour machine no longer has
Imple- residual current (if LOTOTO
mentatio is done)
n ❖ Clean the packer machine
area from flying dust, metal
grams or broken
materials/chips, and other
materials that can hinder the
packer machine process in its
working process.
❖ Check the main hole or parts
when cleaning.

Danger:
• Slip
• Confined space

Prevention:
• Use personal protective
equipment properly such as
safety shoes, safety helmets
and safety gloves.
TOOLS a. Compressor
b. Majun

Total time 1 hour SAFETY

40
mnt

REVISION ➢ Use PPE such as safety helmet, APPROVED

Date REV Desc MGR gloves, goggles, safety shoes, Date SI MGR
safety mask
➢ Make GWP, LST, JPT, closed
space work permits, hot work
permits.

66
 SAFE WORKING PROCEDURES
SWP-Production Cement: Regreasing Packer Machine 66L-PM1

Hazard Present: Personal Protective Personnel Competency

Equipment (PPE) or & Training
Devices Required: Requirenment:
• Danger of • Wearpack First Aid Injury
exposure to fine • Safety glasses Handling
dust • Safety shoes
• The danger of • Safety gloves
pinched hands • Safety helmet
• Compressed air • Dust mask
hazard
Safe Working Pecedure:
1. Before doing work, make sure all equipment in the packer is safe.
2. Use the appropriate PPE: safety shoes, safety helmet, safety glasses,
safety mask, earplug, combination gloves, and etc.
3. Prioritize safety and work safety factors (use PPE), complete and in
accordance with the signs installed in the work area.
4. Make sure the type of grease contained in the grease gun matches the
grease which will be added to the bottom bearing.
5. Regreasing is performed only when performed only when the engine is
operating.
6. Record the magnitude of the vibration and temperature (before and after
the addition of grease) and also the actual amount of grease added.
7. Measure the bearing temperature before adding grease.
8. Make sure there is a grease fitting on the bearing.
9. 2 Clean the grease fitting and around the grease fitting using a cloth
cleaner.
10. Open the drain plug cover.
11. Connect the grease gun nozzle to the grease fitting of the motor.
12. Install the probe vibration and noise meter ( Adash ) in the measuring
position vertical vibration.

67
13. Pump grease according to the predetermined amount slowly with a full
stroke.
14. Remove the nozzle from the grease fitting after adding grease is complete.
15. During the process of adding grease, pay close attention to vibrations and
noise as measured by vibration and noise meter.
16. Measure the temperature of the bearing after the addition of grease is
complete.
17. Stop adding grease if there is grease coming out of the grease fittings.
18. Let the old grease out of the drain plug for 15 minutes.
19. Check the condition of the old grease, whether there is dirt and water
20. Replace the drain plug cover.
21. Clean grease fitting and drain plug area.
22. Report any abnormal noise, grease contamination
23. Duration, temperature and all other abnormal findings.
24. Update the data on the maintenance card contained in the appropriate
bearing with actual conditions.

68
SCHEMATIC FOR THE ENTRY OF GREASE INTO THE BOTTOM
BEARING 66L-PM1

With Spesification:
- Use hoses 14 inch
- The long of hose is more or less of 1 meter.
- If automatic grease, we can add hoses to connect until buttom bearing 66L-
PM1.

In the fourth recommendation where we shorten the grease pipe line by

considering several things:
- In order for grease to enter the bottom bearing more quickly
- So that grease does not pass through a lot, do pipes that have a greater risk of
leaking
- So that grease can be checked more easily
- Simplify the maintenance process

69
PREVENTIVE MAINTENANCE SCHEDULE ALL PACKER MACHINE
FOR ONE MONTH

70
THE JOB DESCRIPTION OF PACKER MACHINE

71