Voice of

PROJECT CHARTER
Business Case Opportunity - Batuhijau Branch

This project is inline with our CSF for MARC. Currently the cost of Unscheduled Maintenance for

Customer/Biz
793 PM’s form a large part of MARC agreement, Engine, Brake, and Suspension is US$ 1 M p.a
which requires robust processes to ensure profitability
is maintenance. The other opportunity come from the machine hours
that we can sell.
Our opportunity is estimated US$ 904K p.a 300
Goal Statement Project Scope
In Scope :
1. Scheduling of the PM (PM Accuracy) 250 Current Performance

Hour/Month/Truck
Y=f(X
2. Supply of Facilities and Labour
Y= Reduce downtime hours between scheduled 3. Performance of Defect Jobs
maintenance events due to Engine, Brake, Out Scope: 200
and Suspension 1. Performing the PM including Condition Monitoring &
X= High quality of scheduled maintenance events Inspections
150

Focus 100

Mean
ID Task N ame
Aug 1 Aug 12 Aug 23 Sep 3 Sep 14 Sep 25 Oct 6

50
8/10 8/12 8/14 8/16 8/18 8/20 8/22 8/24 8/26 8/28 8/30 9/1 9/3 9/5 9/7 9/9 9/11 9/13 9/15 9/17 9/ 19 9/21 9/23 9/25 9/27 9/29 10/1 10/3 10/5 10/7

GAP!
1 Dedicated Supervisor for PM
2 Dedicated TA for PM
3 Day and Night Foreman
4 Review Level and Ratio for PM Crew

Desired Level
5

0
6 PM Crew Train ing
7 Meeting about scope
8 Send feedback all information to TC
9 TC, find out tailored training for PM
10 Appr oval from GOM/PO

1 19 37 55 73 91 109 127 145 163 181 199 217 235 253 271
•Reduce Unscheduled
11 Preparing Instruct or
12 Kick of training
13
14 PM Trolley
15
16
17
R edesign due to additional requirement
Send layout to BAC Aussie/BAC will review
Get quotation from BAC
Sep 01 - Feb 02

Downtime to 29.31 hr/month

18 Appr oval from GOM/PO
19 Built Trolley and send to BHJ
20 Preparation tool/parts/procedure to trolley
21 H ow to us e - to m ech
22 Kick off
23
24 PM Ch ecksheet - review
25 PM Chec ksheet- finalize
26 Team preparation
27 Training

•Increase Availability of
28 Kick Off Piloting- Pm - str uctured
29
30 Maint enance Strategy
31 Installing air filter for Wastegate line
32 Find out candidate truck
33 Open job
34 Ordering part s
35 Perform replacement

Process? machine to 92 %
Process : Preventive Maintenance

SOLUTION ! Process : Preventive Maintenance service

Sub Process
Sub-processes
Receive Inspect Perform Testing Adjusting Delivery
Receiving Inspect Performing Testing Adjusting Delivery
Clean Machine Conditioning Monitoring PM Testing Adjusting Clean up machine
Pre Inspection Inspect Frame Contamination Control Calibration Clean cabin Clean machine Conditioning monitoring Perform PM Perform Test as per PM's required Clean up
Backlog Performance Test Post inspection
Stratifi
General Inspection
Inspect Frame
Backlog/Defect
Contamination control
Perform Test as per appropriate repair Clean cabin
General Inspection

Environment Machine People

lack of skill
cation
improper training
dusty

Improve
mechanic
weather
watering road
lack of supervision
habit/awareness
Improve 793C Downtime Hour per Major Component
Road mtc
10% engine problem, come from
air filter restriction
100
clean interval/process
793C Breakdown by Engine Comp Cd
20000
Focus only
Maintenance Strategy

# interval to replace for Engine, 80

Stratification
Material Methode
700 100 Brake

Percent
60
system &

Count
600
80
Analyze 10000
500
Suspension 40
Percent

60
Count

400

300 40 20
200
20
100 0 0
0 0
Defect
Defect
Count 64 54 51 48 36 31 28 27 25 24 24 23 264
Count 4925.873689.85
2 687.652663.322015.44
1 101.16 983.51 389.53 378.17 318.53295.93 729.26
Percent 9 8 7 7 5 4 4 4 4 3 3 3 38 Percent 24.4 18.3 13.3 13.2 10.0 5.5 4.9 1.9 1.9 1.6 1.5 3.6
Cum % 9 17 24 31 36 41 45 48 52 56 59 62 100 Cum % 24.4 42.7 56.0 69.2 79.2 84.7 89.5 91.5 93.3 94.9 96.4 100.0