starch plant downtime wb june 2011
TRANSCRIPT
-
8/6/2019 Starch Plant Downtime WB June 2011
1/139
Downtime AnalysisMonth :June-11
Year :2011
Prod Cap. 210 MT
DayBreakdown Starch Volume (MT) Raw Material
Time (hrs) Downtime Volume Quality Peeler Washer
1 16.69 146.00 64.00 15.67 0.00 0.00 0.00 0.00
2 20.13 176.10 33.90 20.13 0.00 0.00 0.00 0.00
3 17.63 154.30 55.70 17.42 0.00 0.00 0.00 0.00
4 24.00 210.00 0.00 24.00 0.00 0.00 0.00 0.00
5 18.14 158.70 51.30 16.00 1.92 0.00 0.00 0.00
6 18.29 160.00 50.00 16.22 0.00 0.00 0.00 0.00
7 22.34 195.50 14.50 21.92 0.43 0.00 0.00 0.00
8 8.97 78.50 131.50 4.00 0.23 0.00 0.00 0.00
9 24.00 210.00 0.00 24.00 0.00 0.00 0.00 0.0010 5.14 44.98 165.03 1.75 2.23 0.00 0.13 0.00
11 19.52 170.83 39.18 19.52 0.00 0.00 0.00 0.00
12 3.35 29.33 180.68 1.75 1.43 0.00 0.00 0.00
13 15.94 139.45 70.55 14.17 1.54 0.00 0.00 0.00
14 5.83 51.00 159.00 4.00 1.04 0.00 0.00 0.00
15 24.00 210.00 0.00 24.00 0.00 0.00 0.00 0.00
16 2.69 23.50 186.50 1.58 0.30 0.00 0.00 0.00
17 21.01 183.80 26.20 21.01 0.00 0.00 0.00 0.00
18 5.54 48.50 161.50 1.42 2.24 0.00 1.83 0.00
19 17.14 150.00 60.00 17.09 0.00 0.00 0.00 0.00
20 18.85 164.90 45.10 0.00 0.35 0.00 0.00 0.3321 5.20 45.50 164.50 0.00 0.00 0.00 0.00 0.00
22 3.42 29.90 180.10 0.33 0.00 0.00 0.00 0.00
23 16.66 145.80 64.20 15.75 0.37 0.00 0.00 0.00
24 18.52 162.05 47.95 18.52 0.00 0.00 0.00 0.00
25 7.09 62.05 147.95 4.08 0.00 2.13 0.00 0.00
26 19.15 167.60 42.40 17.17 0.00 0.00 0.00 0.00
27 18.86 165.05 44.95 17.50 1.20 0.00 0.00 0.00
28 6.39 55.90 154.10 3.92 2.06 0.00 0.00 0.00
29 15.83 138.50 71.50 15.75 0.00 0.00 0.00 0.00
30 3.76 32.90 177.10 3.00 0.18 0.00 0.00 0.00
31 0.00 0.00 210.00 0.00 0.00 0.00 0.00 0.00
TOT 424.07 3710.63 2799.38 361.64 15.49 2.13 1.96 0.33
ActualProductio
n
Hoper &Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
2/139
-
8/6/2019 Starch Plant Downtime WB June 2011
3/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump
0.13 0.00 0.00 0.00 0.10 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.22 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.11 0.00 0.00 0.00 0.00
0.00 0.00 0.00 2.07 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 4.00 0.20 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.001.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.18 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.08 0.00 0.00 0.15 0.00 0.00 0.00 0.00 0.00
0.13 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.25 0.05 0.00 0.50 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.05 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.05 0.00 0.00 0.00 0.00
0.00 0.00 0.50 0.00 0.00 0.00 0.00 0.00 0.000.33 0.00 1.34 0.17 0.36 0.00 0.00 0.00 0.00
0.33 0.00 0.00 0.00 2.17 0.00 0.00 0.00 0.00
0.17 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.04 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.17 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.42 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.08 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
3.22 0.05 1.84 6.88 3.16 0.00 0.00 0.22 0.00
Extractor
Separator
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
4/139
-
8/6/2019 Starch Plant Downtime WB June 2011
5/139
Electrical UtilityLogistic
PLN Fork Lift
0.00 0.00 0.00 0.79 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.11 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.54 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.67 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
17.67 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.003.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.58 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.38 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.83 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 1.99 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.58 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
23.29 0.58 0.00 3.26 0.00 0.00 0.00 0.00 0.00
ManPower
Generator
Cable,Motor &Control
Hot OilBoiler
WheelLoader
DeepWell
/Water
-
8/6/2019 Starch Plant Downtime WB June 2011
6/139
-
8/6/2019 Starch Plant Downtime WB June 2011
7/139
Others
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.000.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.000.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
PlanedShutdown
-
8/6/2019 Starch Plant Downtime WB June 2011
8/139
-
8/6/2019 Starch Plant Downtime WB June 2011
9/139
Down Time Analysis for the Production Units
Plant Code : 1 Note: plant code 1
Plant Name : Way Bungur 2
Factory Head : N. Minarta 3
Production Head : Heru T. 4
Month : June-11 5
No. Description UOM 1-Jun-11 2-Jun-11
I Roots
1 Roots Shortage MT 137.08 176.10
2 Roots Quality MT
II Mechanical equipment
1 Hoper and belt conveyor MT
2 Peeler MT
3 Washer MT
4 Choper MT 1.17
5 Rasper MT6 Extractor MT
7 Separator MT
8 DHC MT 0.87
9 Dryer MT
10 Shifter & bagging MT
11 Pipe and screw conveyor MT
12 Pump MT
III Electrical MT
1 PLN
2 Generator MT
3 Line, Motor and Control
IV Utility MT1 Hot Oil Boiler 6.88
2 Wheel Loader
3 Fork Lift
4 Deep well / Water supply
V Logistic (spare/cons. parts, delivery) MT
VI Man power MT
VII Planed shutdown MT
VIII Others
Total Daily Downtime MT 146.00 176.10
Daily Production (actual) MT 64.00 33.90
Daily Production Capacity MT 210.00 210.00
-
8/6/2019 Starch Plant Downtime WB June 2011
10/139
for WB
for KB
for BTJ
for U2
for SIP
3-Jun-11 4-Jun-11 5-Jun-11 6-Jun-11 7-Jun-11 8-Jun-11 9-Jun-11
152.40 210.00 140.00 141.88 191.77 8.75 210.00
1.92 3.73 5.15
52.50
18.12 2.63
0.96
1.90
9.48
0.96
154.30 210.00 143.84 160.00 195.50 78.50 210.00
55.70 - 51.30 50.00 14.50 131.50 -
210.00 210.00 195.14 210.00 210.00 210.00 210.00
-
8/6/2019 Starch Plant Downtime WB June 2011
11/139
10-Jun-11 11-Jun-11 12-Jun-11 13-Jun-11 14-Jun-11 15-Jun-11 16-Jun-11
15.31 170.83 15.31 123.96 35.00 210.00 13.85
19.47 12.48 13.45 9.07 2.65
1.09
9.10 1.53 0.73 1.09 2.19
0.48
1.31 4.33
5.83
44.98 170.83 29.33 139.45 51.00 210.00 23.50
165.03 39.18 180.68 70.55 159.00 - 186.50
210.00 210.00 210.00 210.00 210.00 210.00 210.00
-
8/6/2019 Starch Plant Downtime WB June 2011
12/139
17-Jun-11 18-Jun-11 19-Jun-11 20-Jun-11 21-Jun-11 22-Jun-11 23-Jun-11
183.80 12.40 149.52 2.92 137.81
19.62 3.03 3.25
16.04
2.92
2.92 2.92 1.46
4.38 25.52
1.46
0.44 0.48 3.15 18.96
154.58 26.25
5.10
3.28
183.80 48.50 150.00 164.90 59.30 29.90 145.80
26.20 161.50 60.00 45.10 164.50 180.10 64.20
210.00 210.00 210.00 210.00 223.80 210.00 210.00
-
8/6/2019 Starch Plant Downtime WB June 2011
13/139
24-Jun-11 25-Jun-11 26-Jun-11 27-Jun-11 28-Jun-11 29-Jun-11 30-Jun-11
162.05 35.73 150.21 153.13 34.27 137.81 26.25
10.47 17.98 1.55
18.66
1.46 3.65
0.36 0.69
7.29 5.10
17.39
162.05 62.05 167.60 165.05 55.90 138.50 32.90
47.95 147.95 42.40 44.95 154.10 71.50 177.10
210.00 210.00 210.00 210.00 210.00 210.00 210.00
-
8/6/2019 Starch Plant Downtime WB June 2011
14/139
1-Jul-11 mtd %
3,138.13 84.60% from total downtime
123.80 3.34% from total downtime
18.66 0.50% from total downtime
17.14 0.46% from total downtime
2.92 0.08% from total downtime
28.20 0.76% from total downtime
0.48 0.01% from total downtime29.90 0.81% from total downtime
59.60 1.61% from total downtime
45.70 1.23% from total downtime
0.96 0.03% from total downtime
- 0.00% from total downtime
208.54 5.62% from total downtime
5.10 0.14% from total downtime
- 0.00% from total downtime
28.51 0.77% from total downtime
- 0.00% from total downtime
- 0.00% from total downtime
- 0.00% from total downtime
- 0.00% from total downtime
- 0.00% from total downtime
- 0.00% from total downtime
- 0.00% from total downtime
- 3,709.56 56.99% from max. capacity
-
210.00 2,799.38 43.01% from max. capacity
-
210.00 6,508.94
-
8/6/2019 Starch Plant Downtime WB June 2011
15/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 0:00 0:00 0.00 0.00 0.00
2 0:00 0:00 0.00 0.00 0.00
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 0.00 0.00 0.00
Daily Production (Capacity - Breakdown) 210.00
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
16/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
17/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
18/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
19/139
1
Production capacity: 210 MT/da
Problem
1 PLN off ### 0:00
2 PLN on 0:00 0:30
3 Process stop due to raw material shortage 4:00 7:00
4 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk ### ###
5 0:00 0:00
6 0:00 0:00
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
20/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
0.08 1.00 0.73 0.08
0.50 1.00 4.37 0.50
3.00 1.00 26.25 3.00 3.00
1.77 0.10 1.55 0.18 0.18
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
5.35 32.90 3.76 3.00 0.18 0.00 0.00 0.00
177.10 3.76
26.25 1.55 0.00 0.00 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
21/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.08
0.50
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.58
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 5.10
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
22/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
23/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage 7:00 ### 15.00 1.00 131.25 15.00
2 Start up process ### ### 0.75 1.00 6.56 0.75
3 DHC run 2 unit due to temperature boiler drop ### ### 0.75 0.10 0.69 0.08
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 16.50 138.50 15.83
Production 71.50
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
24/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
15.00
0.75
15.75 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
15.83
137.81 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
25/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.08
0.08 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.69 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
26/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
27/139
1
2
3
4
5
6
7
8
-
8/6/2019 Starch Plant Downtime WB June 2011
28/139
Production capacity:
Problem
Start up process
Root chopper overload
Root chopper overload
Root chopper overload
Root chopper overload
Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk and also many stone
Process stop due to raw material shortage
Total Breakdown Time
Production
-
8/6/2019 Starch Plant Downtime WB June 2011
29/139
1
210 MT/day
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler
7:00 7:45 0.75 1.00 6.56 0.75 0.75
### ### 0.08 1.00 0.73 0.08
### ### 0.17 1.00 1.46 0.17
### ### 0.08 1.00 0.73 0.08
### ### 0.08 1.00 0.73 0.08
7:45 3:50 20.08 0.10 17.98 2.06 2.06
3:50 7:00 3.17 1.00 27.71 3.17 3.17
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
24.42 55.90 6.39 3.92 2.06 0.00 0.00
154.10 6.39
34.27 17.98 0.00 0.00
X Check 0.00 OK
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
30/139
Mechanical Problem
Washer Choper Rasper DHC Dryer Sifter Pump PLN
0.08
0.17
0.08
0.08
0.00 0.42 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 3.65 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
31/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
32/139
1
Production capacity: 210 MT/da
Problem
1 Root chopper no.2 overload 7:20 7:25
2 Root chopper no.1&2 overload ### ###
3 Root chopper no.2 overload ### ###
4 Process stop due to raw material shortage ### 7:00
5 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 7:00 ###
6 0:00 0:00
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
33/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
0.08 0.50 0.36 0.04
0.08 1.00 0.73 0.08
0.08 0.50 0.36 0.04
17.50 1.00 153.13 17.50 17.50
6.50 0.18 10.47 1.20 1.20
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
24.25 165.05 18.86 17.50 1.20 0.00 0.00 0.00
44.95 18.86
153.13 10.47 0.00 0.00 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
34/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.04
0.08
0.04
0.17 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.46 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
35/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
36/139
1
Production capacity: 210 MT/day
Problem
Break Down
1 Process stop due to raw material shortage 7:00 ### 16.00 1.00 140.00
2 Strat up process ### 0:10 1.17 1.00 10.21
3 Boiler temparature drop due to coal difficult to burn 0:10 6:40 6.50 0.31 17.39
4 0:00 0:00 0.00 0.00
5 0:00 0:00 0.00 0.00
6 0:00 0:00 0.00 0.00
7 0:00 0:00 0.00 0.00
8 0:00 0:00 0.00 0.00
0:00 0:00 0.00 0.00
0:00 0:00 0.00 0.000:00 0:00 0.00 0.00
0:00 0:00 0.00 0.00
0:00 0:00 0.00 0.00
0:00 0:00 0.00 0.00
Total Breakdown Time 23.67 167.60
Production 42.40
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
37/139
* put number from duration column
Raw Material Mechanical
Time Volume Quality Peeler Washer Choper Rasper
16.00 16.00
1.17 1.17
1.99
0.00
0.00
0.00
0.00
0.00
0.00
0.000.00
0.00
0.00
0.00
19.15 17.17 0.00 0.00 0.00 0.00 0.00 0.00 0.00
19.15
150.21 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
-
8/6/2019 Starch Plant Downtime WB June 2011
38/139
roblem Electrical Util
DHC Dryer Sifter Pump PLN
1.99
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.99 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 17.39 0.00
Separato
r
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
-
8/6/2019 Starch Plant Downtime WB June 2011
39/139
ity
Others
0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
40/139
1
Production capacity: 210 MT/day
Problem
Break Down
1 Process stop due to raw material shortage 7:00 7:20 0.33 1.00
2 Start up process 7:20 8:35 1.25 1.00
3 DHC no.2 overload ### ### 0.17 0.25
4 PLN off and Switch on genset ### ### 0.08 0.50
5 PLN on and switch off genset ### ### 0.42 0.50
6 PLN off and Switch on genset ### ### 0.08 1.00
7 PLN on and switch off genset ### ### 0.50 1.00
8 Gearbox hopper distributor trouble ### ### 0.17 1.00
9 Hopper distributor rasper run manual due to gearbox trouble ### 4:30 7.50 0.26
10 Process stop due to raw material shortage 4:30 7:00 2.50 1.0011 0:00 0:00 0.00
12 0:00 0:00 0.00
0:00 0:00 0.00
0:00 0:00 0.00
Total Breakdown Time 13.00
Production
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
-
8/6/2019 Starch Plant Downtime WB June 2011
41/139
* put number from duration column
Raw Material Me
Time Volume Quality Peeler Washer Choper Rasper
2.92 0.33 0.33
10.94 1.25 1.25
0.36 0.04
0.36 0.04
1.82 0.21
0.73 0.08
4.38 0.50
1.46 0.17 0.17
17.21 1.97 1.97
21.88 2.50 2.500.00 0.00
0.00 0.00
0.00 0.00
0.00 0.00
62.05 7.09 4.08 0.00 2.13 0.00 0.00 0.00 0.00
147.95 7.09
35.73 0.00 18.66 0.00 0.00 0.00 0.00
X Check 0.00 OK
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
42/139
chanical Problem Electrical
DHC Dryer Sifter Pump PLN
0.04
0.04
0.21
0.08
0.50
0.00 0.00 0.04 0.00 0.00 0.00 0.00 0.83 0.00 0.00
0.00 0.00 0.36 0.00 0.00 0.00 0.00 7.29 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
-
8/6/2019 Starch Plant Downtime WB June 2011
43/139
Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
44/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage ### 7:00 18.52 1.00 162.05 18.52
2 0:00 0:00 0.00 0.00 0.00
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 18.52 162.05 18.52
Production 47.95
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
45/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
18.52
18.52 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
18.52
162.05 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
46/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
47/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
48/139
1
Production capacity: 210 MT/da
Problem
1 Process stop due to raw material shortage 8:15 ###
2 Temperature boiler un stabil (drop) 7:00 8:15
3 Start up process ### 0:00
4 Root chopper overload 2:10 2:20
5 Root chppper run 1 unit due to root chopper no.2 trouble 4:15 4:25
6 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 0:00 3:42
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
49/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
14.92 1.00 130.52 14.92 14.92
1.25 0.30 3.28 0.38
0.83 1.00 7.29 0.83 0.83
0.17 0.50 0.73 0.08
0.17 0.50 0.73 0.08
3.71 0.10 3.25 0.37 0.37
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
21.05 145.80 16.66 15.75 0.37 0.00 0.00 0.00
64.20 16.66
137.81 3.25 0.00 0.00 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
50/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.08
0.08
0.17 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.46 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
51/139
Electrical Utility
Others
0.38
0.00 0.00 0.38 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 3.28 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
52/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Automatic valve damaged milk DHC no.2 7:00 8:30 1.50 0.69 9.06 1.04
2 DHC No 4 overload and replace cloth DHC 7:40 8:30 0.83 0.50 3.65 0.42
(DHC run 2 unit)
3 DHC run 3 units 8:30 ### 2.17 0.33 6.26 0.72
4 Test 1000 KVA generator, 1000 KVA,1250 kVA ### ### 0.17 1.00 1.46 0.17
5 Over generators to PLN ### ### 0.42 1.00 3.65 0.42
6 8. Chopper 1, 2 trip ### ### 0.33 1.00 2.92 0.33
7 Process stop due to raw material shortage 6:40 7:00 0.33 1.00 2.92 0.33
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 5.75 29.90 3.42
Production 180.10
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
53/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
0.33
0.33
0.33 0.00 0.00 0.00 0.00 0.33 0.00 0.00 0.00
3.42
2.92 0.00 0.00 0.00 0.00 2.92 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
54/139
Electrical Utility
DHC Dryer Sifter Pump PLN
1.04
0.42
0.72
0.17
0.42
2.17 0.00 0.00 0.00 0.00 0.00 0.58 0.00 0.00 0.00 0.00
18.96 0.00 0.00 0.00 0.00 0.00 5.10 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
55/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
56/139
1
Production capacity: 210 MT/day
Problem
Bre
1 Start up process 7:00 7:45 0.75
2 Process stop due to impeller pump tank extractor stage 5 broken ### ### 0.50
3 Start up process ### ### 0.84
4 Process stop due to PLN off and genset trouble ### ### 1.50
5 PLN on and Start up process ### ### 0.75
6 Root chopper no.2 overload 5:00 5:05 0.08
7 Replace v-belt root chopper no.2 5:30 5:45 0.25
8 Separator no. 2 off due to rotation down ### ### 0.17
9 DHC no.2 overload and washing ### ### 0.25
10 DHC no.1 overload 4:00 4:10 0.1711 DHC no.1 overload 6:00 6:10 0.17
12 0:00 0:00 0.00
12 0:00 0:00 0.00
0:00 0:00 0.00
Total Breakdown Time 5.42
Production
Start
(h:m)
End
(h:m)
Duration
(h)
-
8/6/2019 Starch Plant Downtime WB June 2011
57/139
* put number from duration column
ak Down Raw Material
Time Volume Quality Peeler Washer Choper
1.00 6.56 0.75
1.00 4.38 0.50
1.00 7.35 0.84
1.00 13.13 1.50
1.00 6.56 0.75
1.00 0.73 0.08 0.08
1.00 2.19 0.25 0.25
1.00 1.46 0.17
1.00 2.19 0.25
0.33 0.48 0.060.33 0.48 0.06
0.00 0.00
0.00 0.00
0.00 0.00
45.50 5.20 0.00 0.00 0.00 0.00 0.00 0.33
164.50 5.20
0.00 0.00 0.00 0.00 0.00 2.92
X Check 0.00 OK
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
58/139
Mechanical Problem Electrical
Rasper DHC Dryer Sifter Pump PLN
0.75
0.50
0.84
1.50
0.75
0.17
0.25
0.060.06
0.00 1.34 0.17 0.36 0.00 0.00 0.00 0.00 3.00 0.00
0.00 11.73 1.46 3.15 0.00 0.00 0.00 0.00 26.25 0.00
Extracto
r
Separato
r
Pipe &screw
convey
Generato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
59/139
Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
60/139
1
Production capacity: 210 MT/da
Problem
1 Coupling washer trouble ### ###
2 Process stop due to checks voltage transformer ### 7:00
3 Extractor tank overload 9:30 ###
4 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 9:52 ###
5 0:00 0:00
6 0:00 0:00
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
61/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
0.33 1.00 2.92 0.33 0.33
17.67 1.00 154.58 17.67
0.50 1.00 4.38 0.50
3.46 0.10 3.03 0.35 0.35
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
21.96 164.90 18.85 0.00 0.35 0.00 0.00 0.33
45.10 18.85
0.00 3.03 0.00 0.00 2.92
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
62/139
-
8/6/2019 Starch Plant Downtime WB June 2011
63/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
64/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage 7:00 ### 15.75 1.00 137.81 15.75
2 Start up process ### 0:05 1.34 1.00 11.71 1.34
3 DHC no.1 overload 4:40 4:50 0.17 0.33 0.48 0.05
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 17.25 150.00 17.14
Production 60.00
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
65/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
15.75
1.34
17.09 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
17.14
149.52 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
66/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.05
0.05 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.48 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
67/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
68/139
1
Production capacity: 210 MT/da
Problem
1 Start up process 7:00 7:55
2 Replacing gearbox motor peeler due to holder gearbox broken ### ###
3 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 8:34 7:00
4 Process stop due to raw material shortage 6:30 7:00
5 DHC no.1 overload 1:20 1:30
6 0:00 0:00
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
69/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
0.92 1.00 8.02 0.92 0.92
1.83 1.00 16.04 1.83 1.83
22.43 0.10 19.62 2.24 2.24
0.50 1.00 4.38 0.50 0.50
0.17 0.30 0.44 0.05
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
25.85 48.50 5.54 1.42 2.24 0.00 1.83 0.00
161.50 5.54
12.40 19.62 0.00 16.04 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
70/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.05
0.00 0.00 0.00 0.00 0.05 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.44 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
71/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
72/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage 9:59 6:50 20.84 1.00 182.34 20.84
2 Start up process 6:50 7:00 0.17 1.00 1.46 0.17
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 21.01 183.80 21.01
Production 26.20
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
73/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
20.84
0.17
21.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
21.01
183.80 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
74/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
75/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
76/139
1
Production capacity: 210 MT/da
Problem
1 Process stop due to raw material shortage 7:00 8:00
2 Start up process 8:00 8:35
3 Separator run 2 unit due to separator no.1 replacing v-belt 8:15 9:45
4 Root chopper overload ### ###
5 Root chopper overload 6:00 6:05
6 Root chopper overload 6:45 6:50
7 Motor rasper no.3 trouble ### ###
8 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk ### ###
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
77/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
1.00 1.00 8.75 1.00 1.00
0.58 1.00 5.10 0.58 0.58
1.50 0.33 4.33 0.50
0.08 1.00 0.73 0.08
0.08 1.00 0.73 0.08
0.08 1.00 0.73 0.08
0.17 0.33 0.48 0.05
3.02 0.10 2.65 0.30 0.30
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
6.52 23.50 2.69 1.58 0.30 0.00 0.00 0.00
186.50 2.69
13.85 2.65 0.00 0.00 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
78/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.50
0.08
0.08
0.08
0.05
0.25 0.05 0.00 0.50 0.00 0.00 0.00 0.00 0.00 0.00
2.19 0.48 0.00 4.33 0.00 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
79/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
80/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage 7:00 7:00 24.00 1.00 210.00 24.00
2 0:00 0:00 0.00 0.00 0.00
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 24.00 210.00 24.00
Production 0.00
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
81/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
24.00
24.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
24.00
210.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
82/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
83/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
84/139
1
Production capacity: 210 MT/da
Problem
1 PLN trip 7:20 7:45
2 Root Chopper overload 0:00 0:00
3 PLN off and direct on ### ###
4 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 8:37 ###
5 Process stop due to raw material shortage 3:00 7:00
6 0:00 0:00
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
85/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
0.42 1.00 3.65 0.42
0.25 0.50 1.09 0.13
0.25 1.00 2.19 0.25
10.37 0.10 9.07 1.04 1.04
4.00 1.00 35.00 4.00 4.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
15.29 51.00 5.83 4.00 1.04 0.00 0.00 0.00
159.00 5.83
35.00 9.07 0.00 0.00 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
86/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.42
0.13
0.25
0.13 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.67
1.09 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 5.83
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
87/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
88/139
1
Production capacity: 210 MT/da
Problem
1 Chopper no.2 overload 8:00 8:05
2 Process stop due to raw material shortage ### ###
3 Start up process ### 0:10
4 Separator no.1 trip due to trouble lectrical (valtage down) 5:30 6:00
5 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 0:10 7:00
6 0:00 0:00
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
89/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
0.08 1.00 0.73 0.08
13.25 1.00 115.94 13.25 13.25
0.92 1.00 8.02 0.92 0.92
0.50 0.30 1.31 0.15
6.83 0.22 13.45 1.54 1.54
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
21.58 139.45 15.94 14.17 1.54 0.00 0.00 0.00
70.55 15.94
123.96 13.45 0.00 0.00 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
90/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.08
0.15
0.08 0.00 0.00 0.15 0.00 0.00 0.00 0.00 0.00 0.00
0.73 0.00 0.00 1.31 0.00 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
91/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
92/139
1
Production capacity: 210 MT/da
Problem
1 Process stop due to raw material shortage 7:00 8:00
2 Start up process 8:00 8:45
3 Root chopper no.2 overload ### ###
4 Root chopper no.2 overload ### ###
5 Root chopper no.1 overload ### ###
6 Root chopper no.2 overload ### ###
7 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 9:00 ###
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
93/139
-
8/6/2019 Starch Plant Downtime WB June 2011
94/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.05
0.04
0.04
0.04
0.18 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.53 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
95/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
96/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage ### 7:00 19.52 1.00 170.83 19.52
2 0:00 0:00 0.00 0.00 0.00
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 19.52 170.83 19.52
Production 39.18
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
97/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
19.52
19.52 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
19.52
170.83 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
98/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
99/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
100/139
1
Production capacity: 210 MT/da
Problem
1 Process stop due to raw material shortage 7:00 8:00
2 Start up process 8:00 8:45
3 Replacing motor hoper distributor rasper due to motor hopper damaged 9:10 ###
4 Hopper peeler clogged due to water empty (automatic pump water off) ### ###
5 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 8:45 7:00
6 Chopper 1&2 overload 2:00 2:07
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
1
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
101/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
1.00 1.00 8.75 1.00 1.00
0.75 1.00 6.56 0.75 0.75
1.83 0.50 8.02 0.92
0.25 0.50 1.09 0.13 0.13
22.25 0.10 19.47 2.23 2.23
0.12 1.00 1.08 0.12
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
26.21 44.98 5.14 1.75 2.23 0.00 0.13 0.00
165.03 5.14
15.31 19.47 0.00 1.09 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
102/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.92
0.12
1.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
9.10 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
103/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
104/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage 7:00 7:00 24.00 1.00 210.00 24.00
2 0:00 0:00 0.00 0.00 0.00
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 24.00 210.00 24.00
Production 0.00
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
105/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
24.00
24.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
24.00
210.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
106/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
107/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
108/139
1
Production capacity: 210 MT/da
Problem
1 Start up process 8:00 9:00
2 Automatic valve DHC no.3 trouble ### ###
3 Separator run 2 unit due to separator no.1 electrical trouble (inverter) 8:00 4:00
4 PLN off + Chopper trip ### ###
5 PLN off ### ###
6 Switch off genset ### ###
7 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk 1:42 4:00
8 Process stop due to raw material shortage 4:00 7:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
109/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
1.00 1.00 8.75 1.00 1.00
1.00 0.20 1.75 0.20
20.00 0.20 35.00 4.00
0.42 0.50 1.82 0.21
0.33 0.50 1.46 0.17
0.33 0.50 1.46 0.17
2.30 0.10 2.01 0.23 0.23
3.00 1.00 26.25 3.00 3.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
28.38 78.50 8.97 4.00 0.23 0.00 0.00 0.00
131.50 8.97
35.00 2.01 0.00 0.00 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
110/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.20
4.00
0.21
0.17
0.17
0.00 0.00 0.00 4.00 0.20 0.00 0.00 0.00 0.00 0.54
0.00 0.00 0.00 35.00 1.75 0.00 0.00 0.00 0.00 4.74
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
111/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
112/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage 9:05 7:00 21.92 1.00 191.77 21.92
2 a lot of rotten root 7:00 9:05 2.08 0.20 3.73 0.43
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 24.00 195.50 22.34
Production 14.50
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
113/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
21.92
0.43
21.92 0.43 0.00 0.00 0.00 0.00 0.00 0.00 0.00
22.34
191.77 3.73 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
114/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
115/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
116/139
1
Production capacity: 210
Problem
1 Process stop due to raw material shortage 7:00
2 start production preparation ###
3 separator number 1 suffered damage to the panel (there are sparks on the panel and inverter) ###
(run 2 unit of separator) 0:00
4 Too Many Rotten Root ###
0:00
0:00
0:00
0:00
0:000:00
0:00
0:00
0:00
Total Breakdown Time
Production
Start
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
117/139
MT/day
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
### 15.17 1.00 132.71 15.17 15.17
### 0.50 0.33 1.44 0.17 0.17
7:00 8.50 0.24 18.12 2.07
0:00 0.00 0.00 0.00
7:00 8.83 0.10 7.73 0.88 0.88
0:00 0.00 0.00 0.00
0:00 0.00 0.00 0.00
0:00 0.00 0.00 0.00
0:00 0.00 0.00 0.00
0:00 0.00 0.00 0.000:00 0.00 0.00 0.00
0:00 0.00 0.00 0.00
0:00 0.00 0.00 0.00
0:00 0.00 0.00 0.00
33.00 160.00 18.29 16.22 0.00 0.00 0.00 0.00
50.00 18.29
141.88 0.00 0.00 0.00 0.00
X Check 0.00 OK
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
118/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
2.07
0.00 0.00 0.00 2.07 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 18.12 0.00 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
119/139
Electrical Utility
Others
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
120/139
1
Production capacity: 210 MT/da
Problem
1 Process stop due to raw material shortage 7:00 ###
2 Start up process ### ###
3 Temperature of boiler low ### ###
4 DHC run 2 unit ### ###
5 Small root (diameter bellow 2.5 cm), hard to get proper thickness of milk ### 5:20
6 0:00 0:00
7 0:00 0:00
8 0:00 0:00
0:00 0:00
0:00 0:000:00 0:00
0:00 0:00
0:00 0:00
0:00 0:00
Total Breakdown Time
Production
Start
(h:m)
End
(h:m)
-
8/6/2019 Starch Plant Downtime WB June 2011
121/139
* put number from duration column
Break Down Raw Material
Time Volume Quality Peeler Washer
15.25 1.00 133.44 15.25 15.25
0.75 1.00 6.56 0.75 0.75
0.33 0.33 0.96 0.11
0.33 0.33 0.96 0.11
6.33 0.30 16.78 1.92 1.92
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.000.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
23.00 158.70 18.14 16.00 1.92 0.00 0.00 0.00
51.30 18.14
140.00 16.78 0.00 0.00 0.00
X Check 0.00 OK
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
Hoper &
Belt
-
8/6/2019 Starch Plant Downtime WB June 2011
122/139
Mechanical Problem
Choper Rasper DHC Dryer Sifter Pump PLN
0.11
0.00 0.00 0.00 0.00 0.11 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.96 0.00 0.00 0.00 0.00 0.00
Extracto
r
Separato
r
Pipe &screw
convey
-
8/6/2019 Starch Plant Downtime WB June 2011
123/139
Electrical Utility
Others
0.11
0.00 0.00 0.11 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.96 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
124/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage 7:00 7:00 24.00 1.00 210.00 24.00
2 0:00 0:00 0.00 0.00 0.00
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 24.00 210.00 24.00
Production 0.00
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
125/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
24.00
24.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
24.00
210.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
126/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
127/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
128/139
1
Production capacity: 210 MT/day
Problem
Break Down
1 Process stop due to raw material shortage 7:00 ### 15.00 1.00 131.25
2 Start up process ### ### 0.75 1.00 6.56
3 Repair screw bagging for jumbo bag ### 0:00 1.00 0.22 1.90
4 Process stop due to raw material shortage 5:20 7:00 1.67 1.00 14.58
5 0:00 0:00 0.00 0.00
6 0:00 0:00 0.00 0.00
7 0:00 0:00 0.00 0.00
8 0:00 0:00 0.00 0.00
0:00 0:00 0.00 0.00
0:00 0:00 0.00 0.000:00 0:00 0.00 0.00
0:00 0:00 0.00 0.00
0:00 0:00 0.00 0.00
0:00 0:00 0.00 0.00
Total Breakdown Time 18.42 154.30
Production 55.70
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
129/139
* put number from duration column
Raw Material Mechanical
Time Volume Quality Peeler Washer Choper Rasper
15.00 15.00
0.75 0.75
0.22
1.67 1.67
0.00
0.00
0.00
0.00
0.00
0.000.00
0.00
0.00
0.00
17.63 17.42 0.00 0.00 0.00 0.00 0.00 0.00 0.00
17.63
152.40 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
-
8/6/2019 Starch Plant Downtime WB June 2011
130/139
roblem Electrical Util
DHC Dryer Sifter Pump PLN
0.22
0.00 0.00 0.00 0.00 0.22 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 1.90 0.00 0.00 0.00 0.00 0.00 0.00
Separato
r
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
-
8/6/2019 Starch Plant Downtime WB June 2011
131/139
ity
Others
0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
Fork
Lift
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
132/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage ### 7:00 20.13 1.00 176.10 20.13
2 0:00 0:00 0.00 0.00 0.00
3 0:00 0:00 0.00 0.00 0.00
4 0:00 0:00 0.00 0.00 0.00
5 0:00 0:00 0.00 0.00 0.00
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.000:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 20.13 176.10 20.13
Production 33.90
Start
(h:m)
End
(h:m)
Duration
(h)
CapacityFactor
(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
133/139
* put number from duration column
Raw Material Mechanical Problem
Volume Quality Peeler Washer Choper Rasper
20.13
20.13 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
20.13
176.10 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
X Check 0.00 OK
Hoper &
Belt
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
134/139
Electrical Utility
DHC Dryer Sifter Pump PLN
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Pipe &screw
convey
Generato
r
Cable,Motor &
Control
HotOil
Boiler
WheelLoade
r
Fork
Lift
-
8/6/2019 Starch Plant Downtime WB June 2011
135/139
Others
0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00
Logistic
ManPower
PlanedShut
down
DeepWell /
Water
-
8/6/2019 Starch Plant Downtime WB June 2011
136/139
1
Production capacity: 210 MT/day
Problem
Break Down
Time
1 Process stop due to raw material shortage 7:00 ### 15.25 1.00 133.44 15.25
2 Start up process ### ### 0.42 1.00 3.65 0.42
3 DHC run 2 unit ### ### 0.33 0.30 0.87 0.10
4 Root choper overload 6:20 6:28 0.13 1.00 1.17 0.13
5 Temperature of boiler low ### 1:17 2.62 0.30 6.88 0.79
6 0:00 0:00 0.00 0.00 0.00
7 0:00 0:00 0.00 0.00 0.00
8 0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
0:00 0:00 0.00 0.00 0.00
Total Breakdown Time 18.75 146.00 16.69
Production 64.00
Note: max. prod. capacity
1. WB 210 MT/d N. Minarta Heru T.
2. KB 150 MT/d N. Minarta Arif Z.
3. BTJ 160 MT/d Suryadi Gigik R.4. U2 120 MT/d Suryadi Agus S.
5. SIP 200 MT/d Agung Siswadi
Start
(h:m)
End
(h:m)
Duration
(h)
Capacity
Factor(0.1 - 1.0)
Capacity
(MT)
-
8/6/2019 Starch Plant Downtime WB June 2011
137/139
* put number from duration column
Raw Material Mechanical Problem
Quality Peeler DHC
15.25
0.42
0.10
0.13
15.67 0.00 0.00 0.00 0.00 0.13 0.00 0.00 0.00 0.10
16.69
137.08 0.00 0.00 0.00 0.00 1.17 0.00 0.00 0.00 0.87
X Check 0.00 OK
Volum
e
Hoper
& Belt
Washe
r
Chope
r
Raspe
r
Extracto
r
Separato
r
-
8/6/2019 Starch Plant Downtime WB June 2011
138/139
Electrical Utility
Dryer Sifter PLN
0.79
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.79 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 6.88 0.00 0.00 0.00
Pipe &
screwconvey
Pum
p
Generato
r
Cable,Motor
&Control
Hot
OilBoiler
Wheel
Loader
Fork
Lift
Deep
Well /Water
-
8/6/2019 Starch Plant Downtime WB June 2011
139/139
Others
0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00
Logisti
c
ManPowe
r
Planed Shut
down