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ofcial contacts | [email protected]

+82-2-6009-4611

ICQCC 2015 Changwon, Korea

ICQCC 2015 - Changwon, Korea

Presentation title (Theme)

Sub-title (Initial oals)

! Improving the Performance of Plant 11 – CiteureupFactory "

! Increaing !he Pro"uctivity of Finih #ill Proce at

the Citeureup Plant–11$, from the e%iting capacity

&'( )1*+ tonhour- to the 110( of optimum capacity

)1&+ tonhour-. within * month improvement

perio" "

Name of the circle Q C C #$%& $& T$P

Name of Presenters 1. Ricko Achmadi Putra

2. Hari Winarsa

Company/organization PT. ndocement Tunggal Prakarsa!T"k

Country ndonesia

Paper Title !In'reasing The Prou'tiit* o+ inish ill Pro'ess at the Citeureu. Plant/11,

+rom the eisting 'a.a'it* 34 (16 ton7hour) to 110 4 o+ the o.timum 'a.a'it*

(16 ton7hour)8 within months im.roement .erio"

Name Q C C #$%& $& T$P

#o" Title and $rganization Plant %%! PT. ndocement Tunggal Prakarsa T"k.! Citeureup Plant! West #a&a!

ndonesia

Contact e'mail address (ohanes.(anuarh)indocement.co.id * rommy.septiyandi)indocement.co.id *

Ricko.putra)indocement.co.id *

+CC ,em"ers #ohanes #anuar! Ricko Achmadi! Rommy -eptiandi! Hari Hermansyah! ifi Nuary!

Aas -unandar

Paper Category +C Circle/ -mall roup Acti&ities

0ey Words 1inish ,ill! Production ncrease! $ptimalizationCost -a&ing %S9 9 2:525:35:2 .er-*ear

bstra't

PT. ndocement Citeureup ! West #a&a! ndonesia is the "ig cement factory in single location! %2 plants! %3!3 million

tons capacity! has "een -$ %322% Certificate! 4hich indicated the management commitment in managing impact of

cement manufacturing on the en&ironment. The plant %% is the "iggest capacity 4ith its great potential increase 4ere

decided to &arious support aspect. The management decided to increase the production performance using &arious

engineer supports Plant %% "y $ptimizing 1inish ,ill area! And +CC 56oung $n Top5 team initiated the theme

7ncrease 1inish ,ill Production Capacity n Cement Production Process 1inish ,ill %%A8.

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9y PCA'approach methodology! consist of :

%. Analyze the recent condition and future potential

;. -tratification the issue


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Ste. 1; anuar* until II ebruar* 2013

1::


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Key Performance Indicator Evaluation Result and Absolute Target Score, Collected by Rommy

Target -core : %22

1rom key performance report and discussion 4ith ,r -is4andi as ,anager Plant %%! +CC young on top decide

to impro&e Producti&ity and efficiency esspecially on Capacity fulfillment rate! "ecause this parameter sho4n

that actual capacity is the lo4est performance and it has relation 4ith -'$ strategy so this parameter must "e

impro&ed. This is pro(ect one sheet that intended for +CC 6oung $n Top :

Management Instruction wit !ne Seet Pro"ect from manager, Collected by Rommy

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1::2: a?ing Con'lusion an ormulating the Theme

a 1rom the -W$T Analysis! Plant ,anager &ery concern a"out the -'$ -trategy and 4ould like to

make it "ecame an impro&ement pro(ect

" $n the other hand! the 0P, e&aluate result sho4ing that performance of producti&ity and efficiency

should "e impro&ed

c 9ased on the a"o&e matters! the Plant'%% ,anager decide to "uild the impro&ement team.

Then the theme of this pro(ect is :

1:@:


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#hen the #eam agreed to determine the $nitial %oals that consist of & a

'uantitave target of achievement and the estimated time of ()*! *ycle

time +step 1- as follow &

! Increaing !he Pro"uctivity of Finih #ill Proce at the Citeureup

Plant–11$, from the e%iting capacity &'( )1*+ tonhour- to the

110( optimum capacity )1&+ tonhour-. within * month

improvement perio" "

Suggestion Comment Plant anager ; Please o 'oorination with all .arties, an ta?e su.erise

+or instal on +ile:

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/tep 2 $nalying !he Caue – Perio"e III until I3 Fe4ruary 201'

2$ !he I"enti6cation of 7oot Caue

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28 9eermining :ypotheie" !he 9ominant Caue 4y ;ing 3oting

No Cas!s "" #$ %N #& '' &$ (otal #ankin

)

1 *inis ,ill !rsonn!l rar!l

c!ck!/ i/i!/

5 6 4 4 3 4 26 10

2 ,lo!!s a! not r!c!i!/

trainin) nis ,ill o!rations

6 8 9 6 8 7 44 7

3 %rin) l!ss tan oti,al 13 13 12 13 13 13 77 1

4 in!r ca,!r 1 is worn 9 9 7 9 9 8 51 5

5 a) lt!r is not )oo/ con/ition 8 7 8 8 7 9 47 6

6 'i) #ainall 2 1 2 2 1 3 11 12

7 t!r! sol/ ! an alt!rnati!

laorator ,at!rial

1 3 1 1 2 1 9 13

8 No ow ,!asr!,!nt oints 7 4 5 3 5 5 29 9

9 (!r! ar! lockin) in /ctin)

otl!t C:

3 2 3 7 4 2 21 11

10 N!!/ all car)! 4 5 6 5 6 6 32 8

11 ;at!rial !/ is tin 12 11 11 12 12 12 70 2

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'$ !he :ypothei tet of 9ominant Caue

sin) scatt!r /ia)ra, an/ t! ,ini,, co!ici!nt corr!lation A B 0.714D ECC

ar! al! to ro! t! actal /o,inant cas!s.

C

ndicator of 6 factor : elta Pressure >m"ar

escription : the Rho &alue I 2.@mm

escription : the Rho &alue I 2.@pcs

ndicator of 6 factor : elta pressure >m"ar

escription : the Rho &alue I 2.@D3! itJs mean

this cause is pro&en dominant

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A B 0.9835

A B 0.8967

A B 0.8549

A B 0.9831


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ndicator of 6 factor : Correcti&e Trou"leshooting

escription : the Rho &alue I 2.3%;! itJs mean this

cause is pro&en dominant

3:@: The Con'lusion

11

A B 0.9534

A B 0.9673

A B 0.9412

After eEamined all of dominant causes! 4e kno4 that all of K causes ha&e strong relationship 4ith the

effect. t pro&ed "y the &alue of coefficient correlation >ρ ≥ 2.K%3! as follo4 :


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=o 9ominant Caue p

1 %rin) l!ss tan oti,al 0.9835

2 ;at!rial !/ is tin 0.9831

3 Not oti,al :r)in) ti,! 0.8967

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D::2 Planning o+ Innoation Solution

Dominant Root Cause 1. Drying less than optimal

Why In order to decrease humidity material

What Utilizing the hot air from ESP cooler

Where inish !ill 11"

When "pril # $uly %&1'

Who $ohanes $anuar

(o) 1.

%.

'.

*.

Pro+ect Study

Pro+ect Implementation

,rials

E-aluation

(o) !uch ,arget/ 1&&0 inlet temperature C2P dan tu3e mill H %%&I C

Dominant Root Cause %. !aterial 3ed is thin

Why In order to 4eep material longer to grind in ta3le

What Installing horizotal dam ring


When $uly#1'

Who (ari hermansyah

(o) 1.

%.

'.

*.

Pro+ect Study

Pro+ect Implementation

,rial

E-aluation

(o) !uch ,arget/ 1&&0 C2P 3ed !aterial in good form H %& mm/

Dominant Root Cause '. 5ot optimal Purging time

Why 6ptimizing purging for 3agfilter

What "d+usting the purging time 3ase on delta preasure 3agfilter


When "ugust %&1'

Who Ric4o ".P.

(o) 1.

%.

'.

*.

Chec4 pressure purging

Setting purging time

,rials

E-aluation

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(o) !uch ,arget/ 1&&0 Delta pressure 3ag filter in good condition 17& m3ar/

Dominant Root Cause *. Incorrect installation position mem3ranes

Why "gar mem3ran 3ag filter memili4i life time yang pan+ang

What Install mem3rane on ,op position


When Septem3er %&1'

Who "as Sunandar

(o) 1.

%.

'.

*.

mem3rane condition chec4

!ela4u4an peru3ahan posisi pemasangan mem3ran

,rials

E-aluasi

(o) !uch ,arget/ 1&&0 Damaged mem3ranes decrease less than 8 in 1 month

Dominant Root Cause 8. 9iner cham3er 1 is )orn

Why 6ptimization :rinding material

What Replace liner first cham3er


When 64to3er %&1'

Who (ari (ermansyah

(o) 1.

%.

'.

*.

!easuring thic4 liner

Replace liner for first cham3er

,rials

E-aluation

(o) !uch ,arget/ 1&&0 Replaced liner first cham3er

Dominant Root Cause 7. ;ag filter is not good condition

Why In order to optimize separate material )ith air

What Replace 3agfilter )ith the ne) one


When 5o-em3er %&1'

Who "as Sunandar

(o) 1.

%.

'.

*.

Chec4 condition of filter 3ag

Replace filter 3ag

,rial

E-aluation

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(o) !uch ,arget/ 1&&0 all filter 3ag replaced

Dominant Root Cause


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D:@: Im.lementing o+ Solutions


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and location

3. Compare 4ith delta

preasure

D. Trial another

com"ination >stop

4hen get less delta

preasure

?. 1iE it

K. &aluation

a"o&e data sho4s that the

delta pressure decreased

from ;22 m"ar to %D2

m"ar 4ith a target of %DD

m"ar. The decision 4as

taken this impro&ement

S%CCFSS%G.

ncorrect

installation

position

mem"ranes

,ounting

position of

the

mem"rane

from a"o&e

%. Location nspection

;. esign modification


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S%CCFSS%G:

Liner

cham"er %

is 4orn

Replacing

the liner

cham"er %

%. nspect and analyze

pro"lem

;. Check 1irst liner

cham"er cement mill

4orn liner

D. Take final inpection

"efore test no load

?. After ;D22 Hour

take inspect again

K. &aluation

Decem3er %&1'

Rommy

Conclusion: 1rom the data

a"o&e sho4s that the 4ear

liner cham"er % decreased

from @DM to 2M 4ith a

target of 2M. The decision

4as taken this impro&ement

S%CCFSS%G

mployees

ha&e not

recei&ed

training

finish mill

operations

Conduct

training to

employees

1. !a4e employee list

that need training

%. arranging training

schedule

'. ,raining

*. E-aluation

6cto3er %&1'

Ric4o

Conclusion: 1rom the

a"o&e data sho4s that the

employees 4ho recei&ed

training ha&e increased

from ;2M to %22M 4ith a

target of %22M. The

decision 4as taken this

impro&ementS%CCFSS%G

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Ste. 5; Faluate The Besult / Perio $'tober - &oember 2013

5:: Faluate the Initial oals 'hieement

Conition Perio


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5:


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Ste. ; a?ing Be-StanariAation / Perio >anuar* 201D

:: Stanar o+ Pro'eure

:@: Stanar o+ Besult

After all of the procedures ha&e "een done consistently! then production capacity has the optimum &alue ;%2 Ton

per hour 4ithin ? ,onth.

22

Con'lusion ;@ase on the ata sheet an Baar Chart aboe QCC Per+orman'e alue (H ; 2,20 ) an =or?Pla'eChallenge (# ; 2,00), be+ore im.roement, in Bina =inow, it is lo'ate in Jona C (=or? Per+orman'ean PC


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:C: The Su.eriorit* to ..l* &ew Stanar

Ste. ; Im.lementing the &ew Stanar an


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onitoring Total eeing Cement ill P11 ('tual &ow)


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:@: So'ialiAation o+ &ew Conition in The =or?.la'e

+CC has socialize the ne4 condition in the 4orkplacce 4ith ne4 standard to the all of the employee 4hich has

relation 4ork 4ith 9urning Area! ,aintenance and company management. Conduct to Procedure document le&el

>-$P such as* -$P for operating finish mill for operator central control room! -$P for patroller to check

"agfilter condition.

C:


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Po4er consumsion of finish mill production! that is accoring the data "ello4:

Total Po4er Consumpt

/pei6c Power

Conumpt

!otal

Kwh!on

*inis ;ill & 457.2

*inis ;ill 455.2

Theme statement

9ased on the data sheet a"o&e! it is kno4n that the po4er consumption of the finish mill %%A is still Fuite large

and could still dlakukan optimization. 1or that the neEt time 4e 4ill continue "efore the impro&ement pro(ect!

5Lo4er Po4er Consumption 1inish ,ill Plant %%A5.

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ata -ource : $nline Production Report Reported "y : #anuar ata Period : -eptem"er ecem"er ;2%< =nit : 0WH / Ton


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Program s'heule Su.erior '?nowlege ;

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Ane way to re"uce energy conumption in mill 6nih i 4y lowering powerplay "rive 4y changing the type of lifting from clarifying liner to

claifying liner

qcc young on top for

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