Implementasi Metode Overall Equipment Effectiveness Berbasis Six Big Losses Guna Mengevaluasi Efektivitas Mesin Packing Semen

Integrated maintenance management is an important factor in maintaining the stability of machine operations in manufacturing companies. PT AAAA Factory Gresik is a cement manufacturing company, where the Section Division of Gresik Finish Mill Packer Operation has a problem of downtime cement packing machine 40 kg and causes production delay. This study aims to evaluate the effectiveness of the 40kg cement packing machine as well as to calculate losses due to unproductiveness of the packing machine. Overall Equipment Effectiveness (OEE), Six Big Losses, and Failure Mode and Effect Analysis (FMEA) were used as research method. This study found that OEE value for January-December 2019 of 41.25% are considered as lower percentage in compare with the ideal value of international standards which is 85%. Moreover, the largest average losses are found, namely reduce speed losses, idle and stoppages minor losses and defects in process with percentage in following order, 4.49%, 4.49% and 2.76%.Result from FMEA analysis have been identified 3 highest Risk Priority Number (RPN), namely transportation with an RPN value of 294, the second RPN value of 288 is a blockage in the packing machine, finally the engine button is jammed with an RPN value of 252. The proposed improvement scenario is the start of the engine operating operators checking and cleaning machines regularly and the marketing division expands the sales market.

KADAR DEBU SEMEN TERHIRUP MENGGUNAKAN PERSONAL DUST SAMPLER DAN GANGGUAN FAAL PARU PADA OPERATOR UNIT FINISH MILL

Exposure to dust in the work environment is a potential factor that can cause impaired pulmonary function. Concentration of dust in the air is one factor that affects the severity caused. Higher exposure to dust in the air, increase the risk of impaired pulmonary function. The objective of the research was to analyze the exposure to respirable cement dust and pulmonary function impairment of Finish Mill operators in PT. Semen Indonesia, Tuban Regency. This study used a cross-sectional study design, with the number of sample using purposive sampling method as many as 10 people. The level of inhaled semen dust is measured using a Personal Dust Sampler (PDS). The characteristics of workers are also seen include age, length of employment, smoking habits, use of personal protective equipment and respiratory complaints felt. The results of this study were 90% of operators with respirable dust levels > 3 mg/m3. The highest respirable dust content was 26,7151 mg/m3. The lowest respirable dust content was 1.4665 mg/m3. In addition, 22.2% of operators who have inhaled dust levels > 3 mg/m3 have impaired pulmonary function. Conclusions can be drawn pulmonary function impairment more experienced by operators aged 36 - 45 years, with a working period of more than 15 years. Smoking habits and respiratory history may be seen from operator respiratory complaints.Keywords: finish mill operators, pulmonary function test, respirable cement dust.

Studi Keandalan Motor Induksi Tiga Fasa Main Drive Finish Mill 4.1 PT. Semen Tonasa

Dalam pengoperasian motor induksi 3 fasa diperlukan pengecekan dan pemeriksaan yang disebut maintenance dimaksudkan sebagai tindakan untuk mencegah dan memperbaiki kerusakan yang menjamin tingkat keandalan, dari penelitian penulis menemukan hasil efficiency tingkat keandalan yang memenuhi standarisasi perusahaan dan yang tidak, serta gangguan yang terjadi diantaranya disebabkan oleh bearing rusak, lilitan motor terbakar,serta saluran pendingin / kipas motor tidak berfungsi dan gangguan itu diatasi dengan adanya jadwal perawatan secara mingguan, bulanan, tahunan.

ANALISIS ARC FLASH 6,3 KV PT HOLCIM INDONESIA TBK. BOGOR, JAWA BARAT

<p><em>Protection system is a safety system on electrical equipment in case of interference. One of the electrical hazards is the arc flash. According to IEEE 1584-2002 arc flash is a blast of heat, hot gas, and liquid metal caused by short circuit interference on the equipment. There are 3 cases of arc flash that occurred in PT Holcim Indonesia Tbk. Bogor, West Java. Th</em><em>e aim of this </em><em>research is to find out the amount of arc flash energy in accordance with IEEE 1584-2002 standard, to know </em><em>how much </em><em>the energy, and also</em><em> to</em><em> classify Personal Protective Equipment (PPE) category for the workers according to NFPA 70E-2009 standard. This study was applied to the 5th mill finishing area at PT Holcim Indonesia Tbk. Bogor, West Java. The results showed on the area of the Finish Mill 5 the value of the energy incident is 16.92 cal/cm² on BUS MD-1, 1.39 cal/cm² on BUS RM-1, 1.35 cal/cm² on BUS FN-2, 2.17 cal/cm² on BUS TR-71, 1.41 cal/cm² on BUS TR-72, and 1.34 cal/cm² on BUS TR-73.</em><strong><em> </em></strong></p><p><em>Sistem proteksi merupakan suatu sistem pengaman pada peralatan listrik jika terjadi gangguan. Salah satu bahaya listrik adalah arc flash. Menurut IEEE 1584-2002 arc flash merupakan ledakan panas, gas panas, dan logam cair yang diakibatkan oleh gangguan hubung singkat (short circuit) pada peralatan. Terdapat 3 kasus arc flash yang terjadi di PT Holcim Indonesia Tbk. Bogor, Jawa Barat. Penelitian ini bertujuan untuk mengetahui besar energi arc flash yang sesuai dengan standar IEEE 1584-2002, untuk mengetahui besar energi serta mengklasifikasi kategori Personal Protective Equipment (PPE) bagi pekerja sesuai dengan standar NFPA 70E-2009. Studi ini diterapkan pada area Finish Mill 5 pada PT Holcim Indonesia Tbk. Bogor, Jawa Barat. Hasil penelitian menunjukkan pada area Finish Mill 5 nilai insiden energinya yaitu 16,92 kal/cm² pada BUS MD-1, 1,39 kal/cm² pada BUS RM-1, 1,35 kal/cm² pada BUS FN-2, 2,17 kal/</em><em>cm²</em><em> pada BUS TR-71, 1,41 kal/cm² pada BUS TR-72, dan 1,34 kal/cm² pada BUS TR-73.</em></p>

Penentuan Interval Waktu Pemeliharaan Pencegahan pada Peralatan Sub-Unit RKC 3 di PTX Pabrik Tuban

PT X Tuban Plant has four plants (unit), namely Tuban I, Tuban II, Tuban III and Tuban IV. Each unit plant has three sub units, i.e., Crusher Operations Sub-Unit, Raw Mill, Kiln and Coal Mill (RKC) Sub-Unit and Finish Mill Sub-Unit. RKC 3 Sub-Unit in Tuban III has the highest number of equipment downtime and production loss. Therefore, it was necessary to optimize the time interval of preventive maintenance ( ) and total labor force as part of the company maintenance policy, would also fulfill the required reliability and availability of RKC 3 Sub-Unit. There were two steps in determining Tp optimum. The first step was to obtain the best distribution of the time between failures (TBF) and time to repair (TTR). The next step was to iterate the operating time (Ti) and Tp to determine the minimum preventive maintenance cost rate, reliability and maintainability.This iteration was applied to sub-units of RKC 3 that possesses a series system. Tp at the lowest rate of maintenance costs was the optimum Tp. The optimum Tp for RKC 3 Sub-Unit is 3743,28 hour. The preventive maintenance cost rate for optimum Tp is Rp33.100/hour and the reliability and availability of sub unit are 96,7% and 99,86% respectively.Keywords: reliability, availability, preventive maintenance cost rate, and preventive maintenance

Crucial Mechanism to the Eutectoid Transformation of Wüstite Scale on Low Carbon Steel

It is important to realize the transformation behavior of w&uuml;stite because it greatly affects the final structure of the oxide layer and the surface quality of the steel products. In the present study, the transformation behaviors of the w&uuml;stite layer are examined under nearly-oxygen-free conditions, to simulate the cooling processes after the hot rolled strip is coiled. As the single phase w&uuml;stite was prepared at 950˚C, the 460˚C transformed oxide layer was composed of a mixture of iron and magnetite formed through eutectoid reactions. For the 750˚C-fabricated w&uuml;stite, only magnetite was observed after transformation, without iron precipitates and residual w&uuml;stite. It is speculated that the unusual transformation behavior of the low-temperature-made w&uuml;stite results from the pseudo-structural intermediate phase transformation between w&uuml;stite and magnetite. This pseudo-structure is a pre-transformed w&uuml;stite and of various concentration of ferrous ion, which is determined by the fabrication conditions. During the hot strip mill process, the so-called wet scale, w&uuml;stite, is produced continuously from finish mill to laminar flow sections and ended at 570˚C. Consequently, the final eutectoid transformation below 570˚C is dominantly controlled by the surface temperature ranged from 750˚C to 950˚C for low carbon steel.

Determining Interval Time of Maintenance in Bosowa Cement Indonesia using Reliability Method

Maintenance for machining and production facility is an important aspect to ensure a smooth production process. During this time, it was performed regular maintenance based on technical advice from supplier’s engines which just shows things in general without considering the actual operating conditions. This paper aims to plan the maintenance strategies for the Finish Mill unit based on reliability analysis by considering the target system reliability and cost of improving reliability. The data distribution obtained the most appropriate distribution. Based on the data obtained distribution parameters, then the function of the reliability of each part an be determined so that the value of the reliability of each part and the overall system for a specific time period can be calculated. The results showed that the failure or breakdown Mill Finish Unit was majority caused by the part of 561.BM1, 531.WF1, 531.BC6, 531.BC2, 531.BC1, 561.SR1 and 531.BC3. it means that need to focus o the reliability analysis to allocate their parts.