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WORKSHOP MANAGEMENTIN
PALM OIL MILL
SELAYANG PANDANG
dwisoeprapto@instiper.ac.id
23 October 2013
Workshop Management 1dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Workshop Management 3dwisoeprapto@instiper.ac.id
PALM OIL MILL INDUSTRY
OIL PALM ESTATE
PALM OIL MILL
PALM OIL REFINERY & DOWNSTREAM INDUSTRY
MIDDLE & FINAL PRODUCT
• SDM• ALAT • MESIN• WASTE
Workshop Management 5dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
SDM - Operator
SDM - Mekanik
POM - MACHINERY TECHNOLOGY
SKEMATIKA
Machinery Technology 6dwisoeprapto@instiperjogja.ac.id
Langkah Proses : Nama Alat Mesin : Fungsi : Prinsip Kerja :
Stasiun Pendukung : Alat Mesin Proses
Palm Oil MillPembelian Suku Cadang Alat Mesin
SDM - Operator
Alat Mesin Perbengkelan
Bahan Pelumas Alat Mesin
Perawatan Alat Mesin - Routine
Reparasi Kerusakan Alat Mesin
Pengadaan Suku Cadang Alat Mesin
Energi Listrik
Pengujian Alat Mesin
Workshop Management 7dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
MANAGEMENT
WORKSHOP
POM
Tatakelola atau ilmu / tatacara dalam mengurusi suatu kegiatan
Bengkel / bagian mengurusi kegiatan yang berkaitan dengan keteknikan / alat mesin
Palm Oil Mill / Pabrik Kelapa Sawit
• Pabrik Kelapa Sawit – Palm Oil Mill• Alat Mesin di PKS / POM• Struktur Organisasi di PKS / POM• Lingkup Kerja Asisten Mill• Lingkup Kerja Asisten Workshop • Metoda Pemeliharaan Alat Mesin
– Planned Preventive Maintenance – Breakdown Repair– Penyediaan suku cadang alat mesin
Workshop Management 8dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENTLINGKUP BAHASAN
Workshop Management 10dwisoeprapto@instiper.ac.id
PALM OIL MILL HEAD
ASSISTEN LOGISTIK
ASSISTEN LABORATORIUM
ASSISTEN MAINTENANCE
ASSISTEN PRODUKSI SHIFT B
ASKEP MAINTENANCE
ASKEP PRODUKSI
MILL HEAD
ASSISTEN PRODUKSI SHIFT A
ASSISTEN ELECTRIC
ASSISTEN PROJECT
PKS ADMIN
ASSISTEN QHSE
PKS ADMIN
ASSISTEN PERSONALIA/GA
ASSISTEN DISPATCH & EQUIPMENT
A. STRUKTUR ORGANISASI PABRIK KELAPA SAWIT
POM - WORKSHOP MANAGEMENT
Workshop Management 11dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Lingkup Kerja Asisten Workshop
Lingkup Kerja Asisten Mill
Mengelola sumberdaya Manusia dan Alat mesin untuk tujuan produksi yang tingkat produktivitasnya sesuai.
Mengelola sumberdaya Manusia dan Alat mesin untuk tujuan mengawal / menjaga kehandalan alat mesin produksi.
• Tabel Jadwal Pemeliharaan Alat Mesin – Periode Tahunan– Periode Bulanan
• Tindakan Perbaikan Darurat Alat Mesin
• Pengelolaan Suku Cadang Alat Mesin– Pengadaan – Pembelian Suku Cadang Alsin– Pengadaan – Pembuatan Suku Cadang Alsin– Penyimpanan Suku Cadang Alat mesin
Workshop Management 12dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
• Predictive Maintenance
• Tindakan Mendiagnosa kerewelan Alsin
• Tindakan Menganalisa Hasil Diagnosa
• Tindakan Perbaikan Yang diperlukan
• Tindakan Pembongkaran Alat Mesin, perbaikan & penggantian suku bagiannya
• Tindakan Pemasangan kembali Alat Mesin dan suku bagiannya
Workshop Management 13dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
What is Total Productive Maintenance?
• TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results
Workshop Management 17dwisoeprapto@instiper.ac.id
• TOTAL = All encompassing by maintenance and production individuals working together
• PRODUCTIVE = Production goods and services that meet or exceed customers’ expectations
• MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times
Breakdown of TPM
Workshop Management 18dwisoeprapto@instiper.ac.id
Workshop Management 24dwisoeprapto@instiper.ac.id
Troubleshooting Adalah suatu cara pendekatan sistematik untuk menebak atau melokalisisir terjadinya kegagalan fungsi suatu alat mesin atau system.
POM - WORKSHOP MANAGEMENT
Workshop Management 25dwisoeprapto@instiper.ac.id
Troubleshooting Adalah suatu keahlian yang terlatih, tidak semua proses troubleshooting sama persis.
POM - WORKSHOP MANAGEMENT
Workshop Management 26dwisoeprapto@instiper.ac.id
Troubleshooting Para teknisi cenderung untuk meningkatkan atas keahlian Troubleshooting mereka itu berdasarkan pengetahuan dan pengalaman pribadinya.
POM - WORKSHOP MANAGEMENT
Workshop Management 27dwisoeprapto@instiper.ac.id
Program Preventive maintenance yang baik akan bermanfaat dalam mendukung pengecilan ataupun pengurangan kegagalan fungsi pada suatu alat mesin.
POM - WORKSHOP MANAGEMENT
Preventive maintenance
Workshop Management 29dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENTManagement in all business and organizational activities is the act of getting people together to accomplish desired goals and objectives using available resources efficiently and effectively. Management comprises planning, organizing, staffing, leading or directing, and controlling an organization (a group of one or more people or entities) or effort for the purpose of accomplishing a goal. Resourcing encompasses the deployment and manipulation of human resources, financial resources, technological resources, and natural resources.
Workshop Management 30dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Management in all business and organizational activities is the act of getting people together to accomplish desired goals and objectives using available resources efficiently and effectively..
Management
Workshop Management 31dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Management comprises planning, organizing, staffing, leading or directing, and controlling an organization (a group of one or more people or entities) or effort for the purpose of accomplishing a goal.
Management
Workshop Management 32dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Resourcing encompasses the deployment and manipulation of human resources, financial resources, technological resources, and natural resources.
Management
Workshop Management 33dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Basic FunctionsManagement operates through various functions, often classified as planning, organizing, staffing, leading/directing, and controlling/monitoring.i.ePlanning: Deciding what needs to happen in the future (today, next week, next month, next year, over the next 5 years, etc.) and generating plans for action.Organizing: (Implementation) making optimum use of the resources required to enable the successful carrying out of plans.Staffing: Job Analyzing, recruitment, and hiring individuals for appropriate jobs.Leading/Directing: Determining what needs to be done in a situation and getting people to do it.Controlling/Monitoring: Checking progress against plans.Motivation : Motivation is also a kind of basic function of management, because without motivation, employees cannot work effectively. If motivation doesn't take place in an organization, then employees may not contribute to the other functions (which are usually set by top level management)
Workshop Management 34dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Basic FunctionsManagement operates through various functions, often classified as planning, organizing, staffing, leading/directing, and controlling/monitoring.i.e
Workshop Management 35dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Planning: Deciding what needs to happen in the future (today, next week, next month, next year, over the next 5 years, etc.) and generating plans for action.
Organizing: (Implementation) making optimum use of the resources required to enable the successful carrying out of plans.
Workshop Management 36dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Staffing: Job Analyzing, recruitment, and hiring individuals for appropriate jobs.
Leading/Directing: Determining what needs to be done in a situation and getting people to do it.
Controlling/Monitoring: Checking progress against plans.
Workshop Management 37dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Motivation : Motivation is also a kind of basic function of management, because without motivation, employees cannot work effectively. If motivation doesn't take place in an organization, then employees may not contribute to the other functions (which are usually set by top level management)
Workshop Management 54dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
No Nama Alat Mesin &
Kapasitas
No. Mesin
Bulan ke 1 2 3 4 5 6 7 8 9 10 11 12
1. Weightbridge WB 01 I I
2. Weightbridge WB 02 I I
3. Loading Ram LR 01 I I
4. Loading Ram LR 02 I I
5. Transfer Carriage TC 01 I I I
6. Transfer Carriage TC 02 I I I
7. Sterilizing Unit ST 01 I I S I I S I I S I I M
8. Sterilizing Unit ST 02 M I I S I I S I I S I I
I : Inspection S : Small Repair M : Medium Repair O : Overhaul
Tabel Jadwal Pemeliharaan Alat Mesin – Tahun ...........Palm Oil Mill :........................................................ Lokasi: .........................
Workshop Management 55dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
No Nama Alat Mesin &
Kapasitas
No. Mesin
Bulan ke 1 2 3 4 5 6 7 8 9 10 11 12
9. Tipper Unit TP 01 I I S I
10. Tipper Unit TP 02 I I S I
11. Threshing Unit TH 01 I I I S
12. Threshing Unit TH 02 I S I I
13. Scrap Conveyor SC 01 S I M I
14. Screw Conveyor SCE 01 S I M I
15. Bucket Elevator BE 01 M I S I
16. Digester - Press DP 01 I M I S I M I S I M I S
17. Digester - Press DP 02 I S I M I S I M I S I M
I : Inspection S : Small Repair M : Medium Repair O : Overhaul
Tabel Jadwal Pemeliharaan Alat Mesin – Tahun ........Lanjutan
Workshop Management 56dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Simulasi Tabel Jadwal Pemeliharaan Alat Mesin POM / PKS
Contoh
Simulasi Tabel Jadwal Pemeliharaan Alat Mesin / Planned Preventive Maintenance disusun berdasarkan prediksi awal atas kinerja operasi Alat Mesin yang bersangkutan. Bilamana Alat Mesin tersebut beroperasi lebih berat dari prediksi awal, maka tenggang waktu jadwal pemeliharaan / service sebaiknya diperpendek / lebih sering di-service . Apabila Alat Mesin tersebut beroperasi lebih ringan dari prediksi awal, maka tenggang waktu jadwal pemeliharaan / service dapat diperpanjang / lebih jarang di-service. Tindakan tersebut di atas diambil dengan pertimbangan yang mendalam berdasar pengalaman & kenyataan yang ada.
Workshop Management 57dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
Simulasi Tabel Jadwal Pemeliharaan Alat Mesin POM / PKS
Contoh - Lanjutan
Pertimbangan lainnya adalah bagaimana membagi beban kerja secara seimbang sepanjang tahun kerja pelayananan, dan pada waktu panen puncak diharapkan Alat Mesin dapat beroperasi secara layak menurut SOP yang ada. Pada saat beban operasi POM / PKS memuncak, maka hindarilah pemeliharaan / service berat / membongkar Alat Mesin, sebaiknya digeser waktunya pada saat keadaan telah memungkinkan kita melakukan tindakan tersebut, akan tetapi service ringan / reparasi pemogokan (Breakdown Repair) tetap dilaksanakan sebagaimana mestinya.
Workshop Management 60dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENTKartu Laporan Kerusakan Alat Mesin
Pada hari ini :........................ Tanggal :.......................... Pukul :........... dilaporkan telah terjadi kerusakan / pemogokan Alat Mesin, pada : Suku Bagian Alat Mesin :................................................................... Nama Alat Mesin : ...........................................................No.: ................ Stasiun Proses :.............................................................. Line : ......... Mohon perhatian dan bantuan perbaikannya dengan segera. Terimakasih atas kerjasamanya.
Tanggal : ........................ Mengetahui :........................... Pengawas :.................... Mekanik :................
Berdasarkan laporan kerusakan / pemogokan Alat Mesin, telah dilakukan pada tindakan pemeriksaan dan perbaikan segera pada Alat Mesin yang dimaksud, dengan memerlukan suku cadang : Nama Suku cadang Alat Mesin :........................................................... Spesifikasi : ..................................................... sejumlah: ...................
Workshop Management 62dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
No. Nama Alat / Suku Cadang Jumlah Keterangan
Bon Pengambilan Suku Cadang Alat Mesin
Pengambilan Suku Cadang untuk : Nama Alat Mesin : ...........................................................No.: ................ Stasiun Proses :.............................................................. Line : .........
Tanggal : ........................ Mengetahui :.......................... Penerima :.................... Penyerah :..................
Workshop Management 64dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
No Tanggal
Keterangan untuk Masuk Keluar Sisa Paraf
Kartu Stok Suku Cadang Alat Mesin
Nama Suku Cadang : ..................................... No. Kode : ..................... Spesifikasi khusus : ................................................................................ Nama Alat Mesin : .............................................. Bagian : ..................... Stasiun Proses :...................................................... Line : .........
Workshop Management 66dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
No Tanggal
Keterangan Pemeliharaan Alat Mesin Teknisi Mengetahui
Kartu Riwayat Alat MesinStasiun Proses :............................................................. Line : .........Nama Mesin : ..................................................................No.: ...........Elektro Motor : .........................................; Daya : .........kW / Phasa :........ .........................................; Daya : .........kW / Phasa :........Boks Pelumas :................; Jenis Pelumas :.............; Jumlah :........CC ................; Jenis Pelumas :.............; Jumlah :........CC ................; Jenis Pelumas :.............; Jumlah :........CC
Workshop Management 67dwisoeprapto@instiper.ac.id
POM - WORKSHOP MANAGEMENT
No Tanggal
Keterangan Pemeliharaan Alat Mesin Teknisi Mengetahui
Kartu Riwayat Alat Mesin (Lanjutan)Stasiun Proses :............................................................. Line : .........Nama Mesin : ..................................................................No.: ...........
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