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Factory
Sub-title (Initial Goals)
within 6
months improvement
period
Name of the circle
Name of Presenters
Company/organization
Country
Paper Title
Q C C YOUNG ON TOP
1.
2.
Hari Winarsa
Name
Q C C YOUNG ON TOP
Plant 11, PT. Indocement Tunggal Prakarsa Tbk., Citeureup Plant, West Java,
Indonesia
johanes.januarh@indocement.co.id ; rommy.septiyandi@indocement.co.id ;
Ricko.putra@indocement.co.id ;
QCC Members
Johanes Januar, Ricko Achmadi, Rommy Septiandi, Hari Hermansyah, Difi Nuary,
Aas Sunandar
Paper Category
Key Words
Cost Saving
Abstract
PT. Indocement Citeureup , West Java, Indonesia is the big cement factory in single location, 10 plants, 14,4 million
tons capacity, has been ISO 14001 Certificate, which indicated the management commitment in managing impact of
cement manufacturing on the environment. The plant 11 is the biggest capacity with its great potential increase were
decided to various support aspect. The management decided to increase the production performance using various
engineer supports Plant 11 by Optimizing Finish Mill area, And QCC "Young On Top" team initiated the theme
Increase Finish Mill Production Capacity In Cement Production Process Finish Mill 11A.
According to the SWOT analysis, the Plant-11 Manager decided to execute the S-O Strategy as an
improvement project in his authority area, so he decided to build the QCC Young On Top as the project
executor.
QCC young on top had discussion to determine project to improve production plant P11. We collect
from manager report such as the key performance report yearly :
4
Management Instruction with One Sheet Project from manager, Collected by Rommy
a)
From the SWOT Analysis, Plant Manager very concern about the S-O Strategy and would like to
make it became an improvement project
b)
On the other hand, the KPM evaluate result showing that performance of productivity and efficiency
should be improved
c)
Based on the above matters, the Plant-11 Manager decide to build the improvement team.
Data Sheet : Capacity and Actual of Production Finish Mill Units, Collected by Ricko
Plant11A,
110%
optimum
capacity
(198
ton/hour);
within
months
improvement period
Suggestion & Comment Plant Manager : Please do coordination with all parties, and take supervise
for instal on filed.
Causes
JJ
RS
DN
RA
HH
AS
Total
Rankin
g
Finish
mill
personnel
rarely
26
10
44
checked fluidized
2
13
13
12
13
13
13
77
51
47
High Rainfall
11
12
13
laboratory material
8
29
21
11
32
12
11
11
12
12
12
70
10
10
10
10
11
11
62
11
12
13
11
10
10
67
outlet CKP
10
11
12
Incorrect
installation
position
membranes
13
2.C. Conclusion
Based on Nominal Group Technique voting data above and by using the rule of
nominal group technique formula N (N>6) 7 root causes. The dominan
causes that will be tested at the next step are :
1. Dryer material less than optimal
2. Material bed is too thin
3. Not Optimal Purging time
4. Not Optimal installation for membranes position
5. First chamber is worn now
6. Bad Bag filter performance
7. Employees havent received Operation training
Step 3 : Examining and Verifying the Dominant Causes Periode WW I until
II March 2013
9
3.A.2
3.A.3
To examine the domination of Not Optimal Purging
time
Indicator of X Factor : Inlet pressure (bar)
= 0.8967
3.A.4
To examine
the domination
= 0.8549
Installation Position Membrane
of
Incorrect
10
3.A.5
To examine the domination of Liner Chamber 1 I
worn
Indicator of X Factor : Liner Wearing Out (%)
= 0.9534
3.A.6
To examine the domination of Bag Filter Is Not Good
Condition
Indicator of X Factor : Broken Bag (%)
= 0.9673
3.A.7
To examine the domination of Employees have not
received training finish mill operations
Indicator of X Factor : Frequency Trouble
= 0.9412
11
Dominant Causes
0.9835
0.9831
0.8967
0.8597
0.9534
0.9673
0.9412
operations
Step 4: Planning and Implementing The Improvement Period Mach 2013 and Oct 2013
After examined
all5W2H
solution
from impact
and easy to fix, we decide to take rank 1 for the solution, as
4.A.
Innovation
Solutions
follows :
4.A.1 Solution Selection
No
Solution
1.
Why
What
Where
When
Who
Johanes Januar
How
1.
Project Study
2.
Project Implementation
3.
Trials
4.
Evaluation
100%, inlet temperature CKP dan tube mill 220 C
2.
Why
What
Where
When
July-13
Who
Hari hermansyah
How
1.
Project Study
2.
Project Implementation
3.
Trial
4.
Evaluation
Why
What
Where
When
August 2013
Who
Ricko A.P.
How
1.
2.
3.
Trials
4.
Evaluation
13
Why
What
Where
When
September 2013
Who
Aas Sunandar
How
1.
2.
3.
Trials
4.
Evaluasi
Why
What
Where
When
Oktober 2013
Who
Hari Hermansyah
How
1.
2.
3.
Trials
4.
Evaluation
Why
What
Where
When
November 2013
Who
Aas Sunandar
How
1.
2.
3.
Trial
4.
Evaluation
14
Why
What
Where
When
Oktober 2013
Who
Rommy S.
How
1.
2.
3.
Training
4.
Evaluation
100%, All operator has good skill for operating Cement mill
After all of the dominant factors have been planned to be repaired, hopefully that the Finish mill 11 A
Production capacity can be increased to 198 ton per hour.
Suggestion & Comment Supervisor : Please do coordination with all parties, and take supervise
for install on field.
15
16
SOLUTION
SOLUTION
CAUSES
IDEAS
IMPLEMENTATION
Drying less
Utilize the
1. Project study
than optimal
2. Location survey
Cooler
3. Calculation for
Electrostatic
precipitator
MONITORING
& DECISON
Conclusion:
From
the
5. Install modification
6. Comisioning all
equipment
7. Evaluation
Material
Make and
bed is thin
install the
horizontal
1.
2.
dam ring
July 2013
problem
Rommy
Design additional
modification for
CKP table
3.
4.
5.
6.
Make horizontal
dam ring
Install horizontal
damring in to CKP
increased from 12 mm to 20
Evaluation
improvement
SUCCESSFUL
Purging
time
based on
1.
Agustus 2013
Ricko
2. Make purging
Delta
pressure
maping
3.
Change parameter
(preasure, timing
17
and location)
preasure
Trial another
combination (stop
preasure)
SUCCESSFUL.
6.
Fix it
7.
Evaluation
Incorrect
Mounting
1. Location Inspection
September 2013
installation
position of
2. Design modification
Hari
position
the
3. Install modification
membranes
membrane
to
from above
membranes position
correct
4. Evaluation
Conclusion:
From
the
filter
membrane
this
improvement
SUCCESSFUL.
1.
condition
filter bag
2.
Oktober 2013
problem
Hari
3.
Conclusion:
4.
5.
Evaluation
6.
this
From
the
improvement
18
Liner
Replacing
chamber 1
the liner
is worn
chamber 1
1.
2.
December 2013
problem
Rommy
3.
4.
5.
6.
brocken liner
SUCCESSFUL
Employees
have
not training to
received
employees
October 2013
Ricko
training
schedule
training
finish
Conduct
Evaluation
mill
operations
3. Training
4. Evaluation
Conclusion:
From
the
have
increased
of
100%.
The
19
Period Data
Production Capacity
(Ton per Hour)
Before Improvement
168
After Improvement
210
Conclusion :
Based on the evaluation which was according to data and the graph, it could be concluded that the
result which was achieved by the improvement was appropriate with more than initial goal 210 Ton
per hour (116%).
20
Negative Impact:
1. The quality of the finish mill must be constantly monitored
2. Keep maintenance to the facilities being made in repairs.
Action to minimize negative impact :
1. Carry out sampling and quality control mill finish every hour.
2. Carry out routine maintenance
21
Conclusion :
Base on the data sheet and Radar Chart above QCC Performance Value (X : 2,20 ) and WorkPlace
Challenge (Y : 2,00), before improvement, in Rinda Window, it is located in Zona C (Work Performance
and PCDA activities were at average position)and after improvement of QCC Performance(X : 3,50) and
Workplace challenge (Y : 3,10) , it is located on zone B which mean that almost all of the work performance
were already good and it is achived by using PDCA activities.
22
Step 7: Implementing the New Standard and Defining Next Project Period Feb 2014 Jul 2015
7.A. Monitoring The New Standard
Data Source : Schedule Maintenance
Data Period : Jan 2014 July 2015
Reported by
: Januar and Ricko
Unit
: No of problem
23
Condition
Period Data
No of Problems
Before Improvement
168
After Improvement
210
Replication 1st
211
Replication 2nd
211
Replication 3rd
210
Conclusion: Based on improvement result monitoring can be seen that total feeding capacity
Finish mill 11 A in January 2014 until August 2015 period is consistent for 210 ton per hour. The
Consistency of the improvement result meet positive result.
24
25
Power consumsion of finish mill production, that is accoring the data bellow:
Spesific Power
Consumpt
Total
Kwh/Ton
Finish Mill A
457.2
Finish Mill B
455.2
Theme statement
Based on the data sheet above, it is known that the power consumption of the finish mill 11A is still quite large
and could still dlakukan optimization. For that the next time we will continue before the improvement project,
"Lower Power Consumption Finish Mill Plant 11A".
26
27