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PLANT DEPARTMEN
SEPTEMBER 2022
RAMA PANJI KUSUMA – ISA MUBAROK – M NAUFAL ADITYA - SEPTIAN DWI SAPUTRA – PRANA DESAMBA D R - TAUPIQ RAHMAN SIREGAR – AGUNG SOEGIHIN
2
DAFTAR ISI
1 KPI
2 Maintenance Proses
4 RM Cost
3
KPI PLANT SITE AGM
AGM4 01-PHYSICAL AVAILABILITY SEPTEMBER
EGI POP PLAN ACT UAL ACH%
PC1250SP-8R 1 91,1% 97,2% 106,7%
ACTUAL PLAN ACH%
EC950EL 1 92,3% 98,8% 107,0% 120, 0%
CAT395 2 92,1% 97,7% 106,1%
EC480-DL 10 87,3% 75,2% 86,1%
SY500H 3 91,9% 98,4% 107,1% 100, 0%
PC200-8M0 2 90,6% 90,2% 99,6%
PC210-10M0 3 82,9% 92,9% 112,1%
EC210D 2 91,5% 46,3% 50,6% 80,0%
HEX 219 19X Engine Can't Running Bleeding Fuel Prepare replace fuel pump (Warranty UT) 39.1 30-Sep-22 CLOSE
D85ESS-2A HDZ 018 20-Sep-22 17547 Schedule Replace Undercarriage Replace undercarriage + Repair blade + Repair track frame - 261.6 9-Oct-22 OPEN
Quality controll repair, Tiap service wajib 1 GL
HDZ 025 27-Aug-22 7232 Engine High Blowby Replace engine with routable from BRE 245.2 11-Sep-22 CLOSE
incharge
Use genuine hose for high pressure & critical
HDZ 013 6-Sep-22 21450 Hose TM Leak Replace hose TM and hydraulic 30.9 7-Sep-22 CLOSE
area
Inspect By UT & STD + Action Service + Instal Opt. Seat + Replace Replace Opt Seat Assy (Bracket Opt Seat
GD825A-2 HGD 801 1-Sep-22 29047 PS IV + Sch. Replace Tyre R.3,4 57.6 3-Sep-22 CLOSE
Tyre R3.4 Broken)
HDT 137
P360 HDT 153 Transmission Problem Continue prepare routable TM Pembentukan PIC OVH 441.2 CONTINUE
HDT 160
Continue program replace axle - Target Okt
ALL UNIT Rear Axle Welding axle crack + Replace axle 362.7 CONTINUE
Selesai
HDT 137
Compressor Replace gasket compressor Schecule replace plate timing gear for all unit 334.7 CONTINUE
HDT 140
Retorque u-bolt saat penggantian spring
ALL UNIT Suspension / Spring Replace spring / accessories 365.9 CONTINUE
(torque dilebihkan dari standart)
HDT 140 23-Sep-22 21095 Engine Low Power Replace engine with OVH BRE (HDT 131) 169.7 30-Sep-22 CLOSE
K440 ALL UNIT ABS Problem Penambahan lock brace 124.1 CONTINUE
Trial menggunakan spring genuine (volvo
ALL UNIT Front Suspension / Spring Replace spring 119.7 CONTINUE
product)
HDT 307 6-Sep-22 5364 Draglink Broken Replace draglink - 115.8 10-Sep-22 CLOSE
BW211D-40 HCO 001 22-Sep-22 6719 PS III + Sch. Reseal Travel Motor Reseal Travel Motor + Replace Rubber Travel Motor - 150.1 28-Sep-22 CLOSE
6
KPI PLANT SITE AGM
PICA MTBF
PROBLEM IDENTIFICATION
PREVENTIVE MAINTENANCE DUE DATE STATUS
EGI CN FREQ B/D COMPONENT MTBF
P360 ALL UNIT 14 Rear Suspension / Spring Retorque U-Bolt Setiap Service 1 & 3 CONTINUE
ALL UNIT 7 Air relay valve Inspect Air System Setiap Service CONTINUE
ALL UNIT 5 Front Suspension / Spring Retorque U-Bolt Setiap Service 1 & 3 CONTINUE
ALL UNIT 4 T/M Inner Parts Continue prepare routable TM CONTINUE
7
KPI PLANT SITE AGM
AGM4 03-MTTR SEPTEMBER
EGI POP PLAN ACT UAL ACH%
PC1250SP-8R 1 5 0 150,0%
EC950EL 1 5 2 223,9% 100
CAT395 2 5 1 471,2%
EC480-DL 10 5 5 93,6% 90
SY500H 3 5 2 275,2%
80
PC200-8M0 2 5 2 230,8%
PC210-10M0 3 5 4 120,5% 70
EC210D 2 5 4 113,0%
60
D375A-6R 4 5 11 47,3%
D85ESS-2A 8 5 4 114,6% 50
GD825A-2 1 5 1 352,9%
GD705-5 1 5 4 134,1% 40
120NG 2 5 2 272,7%
30
160K 1 5 1 508,5%
CAT777E 10 5 2 271,2% 20 17
R100E 4 5 17 28,7% 13
11
P360 23 5 13 38,7% 10
5 4 4 4 4 5
2 1 2 2 1 2 1 2
KR440 12 5 5 101,5% 0
0
TRACK EQUIPMENT 36 5 5,15 97,0%
WHEEL EQUIPMENT 58 5 9,93 50,3%
8
KPI PLANT SITE AGM
PICA MTTR
PROBLEM IDENTIFICATION
DOWN CORRECTIVE ACTION PREVENTIVE MAINTENANCE DUE DATE STATUS
EGI CN ACTIVITY DESCRIPTION PROBLEM
TIME
P360 HDT 140 BAD WEATHER 7.8 Low Power E/G Replace Engine + Replace ECU + Synchronization Software 30-Sep-22 CLOSE
ON PROCESS 161.9
HDT 137 BAD WEATHER 3.7 Splitter Abnormal Re-Gasket Pump Oil T/M + Overhoul T/M + Welding Vessel 19-Sep-22 CLOSE
ON PROCESS 150.0
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MAINTENANCE PROSES PLANT SITE AGM
WASHING EQUIP. 100% 457 317 69.4% 81 Schedule terkendala Hujan + 33 Akses Jalan Licin + 7 WF Breakdown + 10 WT Crowded
DM 100% 1147 1011 88.1% 136 Schedule terkendala Hujan
GREASING UNIT 100% 577 456 79.0% 84 Schedule terkendala Hujan, 7 Akses Jalan Licin, 15 Lube Truck Crowded, 15 Cuaca Berkabut
FUEL FLUSHING 100% 70 70 100.0%
OIL FLUSHING 100% 0 0 0.0%
CLEANING UC 100% 27 27 100.0%
PS 100% 181 165 91.2% 16 Unit reschedule service next week (Unit Crodit + Cuaca Buruk)
ACTION PAP 100% 359 378 105.3%
PPM 100% 5 5 100.0%
PPU 100%
REDO PS 100% 30% 3% 10.0%
10
35
11 16 9
5
0 0
PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL
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Perbandingan Berdasarkan Historis
12
KPI PLANT SITE AGM
13
KPI PLANT SITE AGM
Downtime Analysis Mei 2022
14
KPI PLANT SITE AGM
Downtime Analysis Juni 2022
15
KPI PLANT SITE AGM
Downtime Analysis Juli 2022
16
KPI PLANT SITE AGM
Downtime Analysis Agustus 2022
17
Analisa Data
• Downtime By Activity dipengaruhi oleh aktivitas ON PROGRESS, WAITING PART, dan WAITING
PROGRESS BY EXTERNAL.
• Downtime by Component dipengaruhi oleh Periodical Service, Suspension/Spring Part, Differential
and Final Drive Parts.
• Frequency by Component didominasi oleh Periodical Service, Hydraulic Oil Parts, Suspension/Spring
Parts.
• Metode PICA yang dilakukan sudah cukup baik. Dapat dilihat melalui persentase Unschedule
Maintenance yang cenderung turun setiap bulannya.
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RM COST PLANT SITE AGM
RM Cost MtD – 30 September 2022
SEPTEMBR 2022
KETERANGAN COA SAP
PLAN ACTUAL ACH
PLANT DEPARTEMENT
BAHAN PELUMAS 8500400402 Rp 495.534.840 Rp 976.171.196 196,99%
BAHAN PEMBANTU 8500400501 Rp 217.100.625 Rp 117.506.600 54,13%
SUKU CADANG 8500400502 Rp 4.262.222.826 Rp 6.080.817.179 142,67%
UNDERCARRIAGE 8500400503 Rp 408.723.170 Rp 83.135.298 20,34%
PERAWATAN DAN PERBAIKAN ALAT BERAT 8500400504 Rp 276.374.631 Rp 227.431.656 82,29%
WORKSHOP CONSUMABLES 8500400506 Rp 84.058.790 Rp 156.028.216 185,62%
TYRE 8500400507 Rp 1.200.003.296 Rp 269.301.797 22,44%
Rp 6.944.018.178 Rp 7.910.391.942 113,92%
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RM COST PLANT SITE AGM
RM Cost YtD
BAHAN PELUMAS Rp 4.215.973.217 Rp 3.403.209.835 Rp 495.968.580 Rp 461.338.902 Rp 508.346.142 Rp 325.402.600 Rp 936.433.331 Rp 499.621.246 Rp 684.996.962 Rp 693.041.876 Rp 787.937.679 Rp 662.461.181 Rp 802.290.524 Rp 761.344.030
BAHAN PEMBANTU Rp 1.759.869.999 Rp 683.764.332 Rp 327.309.136 Rp 51.853.640 Rp 385.644.000 Rp 56.984.296 Rp 262.689.727 Rp 177.880.396 Rp 239.192.764 Rp 95.166.000 Rp 257.702.227 Rp 105.089.150 Rp 287.332.146 Rp 196.790.850
SUKU CADANG Rp 17.371.198.714 Rp 22.616.762.666 Rp 2.359.289.336 Rp 3.049.805.408 Rp 3.105.526.544 Rp 2.757.172.040 Rp 2.896.183.662 Rp 3.938.272.131 Rp 3.543.770.076 Rp 4.263.585.313 Rp 2.270.917.369 Rp 3.821.032.257 Rp 3.195.511.727 Rp 4.786.895.517
UNDER CARRIAGE Rp 4.281.915.712 Rp 538.583.641 Rp 682.836.606 Rp 76.192.600 Rp 657.019.982 Rp 43.309.650 Rp 856.298.634 Rp 133.036.679 Rp 351.932.562 Rp 116.299.561 Rp 855.569.444 Rp 71.437.751 Rp 878.258.483 Rp 98.307.400
PERAWATAN DAN PERBAIKAN ALAT BERAT Rp 1.269.152.949 Rp 1.215.352.150 Rp 205.467.532 Rp 192.477.558 Rp 184.424.796 Rp 121.375.201 Rp 230.229.643 Rp 189.889.877 Rp 249.884.135 Rp 168.793.166 Rp 160.398.499 Rp 228.309.938 Rp 238.748.344 Rp 314.506.410
WORKSHOP CONSUMABLES Rp 726.300.094 Rp 803.646.426 Rp 117.794.281 Rp 122.638.191 Rp 122.117.417 Rp 122.943.498 Rp 121.076.781 Rp 139.270.414 Rp 122.228.181 Rp 137.479.397 Rp 120.966.017 Rp 127.971.804 Rp 122.117.417 Rp 153.343.122
TYRE Rp 3.017.783.042 Rp 1.782.920.126 Rp 540.419.756 Rp 533.650.667 Rp 139.491.979 Rp 134.158.871 Rp 571.743.747 Rp 563.596.458 Rp 199.599.093 Rp 134.143.898 Rp 757.804.381 Rp 193.735.395 Rp 808.724.086 Rp 223.634.837
TOTAL AGM Rp 32.642.193.727 Rp 31.044.239.176 Rp 4.729.085.226 Rp 4.487.956.966 Rp 5.102.570.860 Rp 3.561.346.156 Rp 5.874.655.523 Rp 5.641.567.201 Rp 5.391.603.773 Rp 5.608.509.211 Rp 5.211.295.617 Rp 5.210.037.476 Rp 6.332.982.728 Rp 6.534.822.166
BAHAN PELUMAS Rp 5.007.649.551 Rp 2.579.132.811 Rp 936.747.902 Rp 795.325.879 Rp 635.389.027 Rp 807.635.736 Rp 495.534.840 Rp 976.171.196 Rp 1.127.895.644 Rp - Rp 761.813.058 Rp - Rp 1.050.269.080 Rp -
BAHAN PEMBANTU Rp 1.335.248.250 Rp 432.863.333 Rp 216.641.250 Rp 190.118.033 Rp 223.571.250 Rp 125.238.700 Rp 217.100.625 Rp 117.506.600 Rp 218.846.250 Rp - Rp 216.641.250 Rp - Rp 242.447.625 Rp -
SUKU CADANG Rp 23.945.118.041 Rp 16.569.283.698 Rp 3.456.570.728 Rp 5.112.178.856 Rp 3.783.211.690 Rp 5.376.287.663 Rp 4.262.222.826 Rp 6.080.817.179 Rp 3.785.546.140 Rp - Rp 4.186.213.119 Rp - Rp 4.471.353.538 Rp -
UNDER CARRIAGE Rp 1.559.848.660 Rp 235.514.195 Rp 444.101.728 Rp 75.346.286 Rp 80.414.758 Rp 77.032.611 Rp 408.723.170 Rp 83.135.298 Rp 95.458.641 Rp - Rp 185.381.445 Rp - Rp 345.768.919 Rp -
PERAWATAN DAN PERBAIKAN ALAT BERAT Rp 1.801.690.320 Rp 580.353.430 Rp 252.714.311 Rp 264.521.633 Rp 297.089.076 Rp 88.400.141 Rp 276.374.631 Rp 227.431.656 Rp 287.830.141 Rp - Rp 319.941.913 Rp - Rp 367.740.248 Rp -
WORKSHOP CONSUMABLES Rp 507.806.942 Rp 546.450.245 Rp 84.058.790 Rp 195.283.351 Rp 85.210.190 Rp 195.138.678 Rp 84.058.790 Rp 156.028.216 Rp 85.210.190 Rp - Rp 84.058.790 Rp - Rp 85.210.190 Rp -
TYRE Rp 7.630.725.190 Rp 1.129.776.309 Rp 1.432.503.410 Rp 662.862.221 Rp 1.696.725.485 Rp 197.612.291 Rp 1.200.003.296 Rp 269.301.797 Rp 1.400.883.170 Rp - Rp 1.126.561.132 Rp - Rp 774.048.697 Rp -
TOTAL Rp 41.788.086.953 Rp 22.073.374.021 Rp 6.823.338.119 Rp 7.295.636.259 Rp 6.801.611.477 Rp 6.867.345.820 Rp 6.944.018.178 Rp 7.910.391.942 Rp 7.001.670.177 Rp - Rp 6.880.610.706 Rp - Rp 7.336.838.296 Rp -
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TERIMAKASIH
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