Pom - Workshop Management 20131023

WORKSHOP MANAGEMENTIN

PALM OIL MILL

SELAYANG PANDANG

[email protected]

23 October 2013

Workshop Management [email protected]

mailto:[email protected]


POM - WORKSHOP MANAGEMENT



PALM OIL MILL INDUSTRY

OIL PALM ESTATE

PALM OIL MILL

PALM OIL REFINERY & DOWNSTREAM INDUSTRY

MIDDLE & FINAL PRODUCT

• SDM• ALAT • MESIN• WASTE





SDM - Operator

SDM - Mekanik

POM - MACHINERY TECHNOLOGY

SKEMATIKA

Machinery Technology [email protected]

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



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


POM - WORKSHOP MANAGEMENTLINGKUP BAHASAN




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




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



• 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









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


• 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













Troubleshooting Adalah suatu cara pendekatan sistematik untuk menebak atau melokalisisir terjadinya kegagalan fungsi suatu alat mesin atau system.



Troubleshooting Adalah suatu keahlian yang terlatih, tidak semua proses troubleshooting sama persis.



Troubleshooting Para teknisi cenderung untuk meningkatkan atas keahlian Troubleshooting mereka itu berdasarkan pengetahuan dan pengalaman pribadinya.



Program Preventive maintenance yang baik akan bermanfaat dalam mendukung pengecilan ataupun pengurangan kegagalan fungsi pada suatu alat mesin.


Preventive maintenance




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.

http://en.wikipedia.org/wiki/Planning

http://en.wikipedia.org/wiki/Organizing

http://en.wikipedia.org/wiki/Staffing

http://en.wikipedia.org/wiki/Leadership

http://en.wikipedia.org/wiki/Control_%28management%29

http://en.wikipedia.org/wiki/Organization

http://en.wikipedia.org/wiki/Resourcing

http://en.wikipedia.org/wiki/Human_resources

http://en.wikipedia.org/wiki/Financial

http://en.wikipedia.org/wiki/Technological

http://en.wikipedia.org/wiki/Natural_resources



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



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

http://en.wikipedia.org/wiki/Planning



Resourcing encompasses the deployment and manipulation of human resources, financial resources, technological resources, and natural resources.

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)



Basic FunctionsManagement operates through various functions, often classified as planning, organizing, staffing, leading/directing, and controlling/monitoring.i.e



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.



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)



































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: .........................



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



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.



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.






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: ...................





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 :..................





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 : .........





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



No Tanggal

Keterangan Pemeliharaan Alat Mesin Teknisi Mengetahui

Kartu Riwayat Alat Mesin (Lanjutan)Stasiun Proses :............................................................. Line : .........Nama Mesin : ..................................................................No.: ...........





















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Pom - Workshop Management 20131023