Eq. Management

DASAR
MANAJEMEN ALAT
BERAT
TUJUAN BERBISNIS
(business purpose)
?
Profit
TUJUAN BERBISNIS
?
Profit = Production - Cost
TUJUAN BERBISNIS
Key Performance Indicator: COST

PRODUCTION UNIT
KELOMPOK DISKUSI
Menurut Kelompok Anda bagaimana ukuran/

rumusan terbaik untuk mengukur tingkat Profit
yang dihasilkan suatu Alat Berat
Waktu diskusi : 10 Menit
Presentasi : 2 menit/kelompok
BUSINESS PURPOSE
Key Performance Indicator: COST

PRODUCTION UNIT
EQUIPMENT MANAGEMENT
(Unit price – Resale Value) + (PM + Repair + Fuel + Op)

Cost Rp/Ton = ------------------------------------------------------------------------------
Operating Hours X Productivity
Rp/Ton x Ton Production

Profit = (Sell Rp/Ton - Cost Rp/Ton)
EQUIPMENT (UNIT)
MANAGEMENT
Application:
- Type
- Size
- Attachment
• Selection (Pemilihan)
• Owning (Memiliki)
• Operation (Operasional) Cost
• Maintenance & Repair
Production Unit
• Replacement (Penggantian)
- Product Quality (Brand)
- Product Support
- Price
Production Unit
- Production Target
- Productivity
• Selection -(Pemilihan)
Safety
- Cost
Production Unit
Production Unit
- Availability (ketersedian)
- Performance
- Durability (Ketahanan)
- Cost
Production Unit
- Cost trend
- Productivity trend
- Obsolete Cost (harga
usang)
Production Unit
- Performance
- Cost
PRODUCTION
INEFFICIENCY
PRODUCTION 8760
PRODUCTION
CAPACITY
(Op. Hour x Prod. per Hour) OPTIMUM Hours
Idle Unsched. Maint. & Unsched

Operating Hours Repairs Sched. Hours
Repairs
Physical Availability
Operating Schedule
Company Working Schedule
Total Hours In 1 Year

Key Performance Indicators (KPI)
Operating Hours
Mechanical Availability : X 100%
Operating Hours + Down Time
Purpose: To indicate level of Maintenance & Repair quality

World Class : Min 92%
Downtime due to:
-Failure (reason specified)
-Maintenance
Example:
Operating Hours = 7000 hours
Downtime = 500 hours
MA = 7000 X 100% = 93%

7000 + 500
Operating Hours
MTBF :
Number of Shutdowns
MTBF : Mean Time Between Failure
Purpose: To indicate level of Maintenance & Repair quality

World Class : Min 60 – 80 hours
Example:
Operating hours = 7000
Number of maintenance = 28
Number of failure = 50
7000
MTBF = 28 + 50 = 90 Hours
# Scheduled Repairs
Maintenance Eff : X 100%
# Total Repairs
8760
Total Repair Hours
Idle Unsched. Maint. & Unsched

Operating Hours Repairs Sched. Hours
Repairs
Physical Availability
Operating Schedule
Company Working Schedule
Total Hours In 1 Year

# Scheduled Repairs
Maintenance Eff : X 100%
# Total Repairs
Purpose: To indicate quality of maintenance, repair and

scheduling
World class: Min 80%
Example:
# Total Repairs = 50
# Unscheduled Repairs = 20
50 - 20
ME = X 100% = 60%
50
Operating Hours
Eff Utilization : X 100%
Operating Hours + Idle + Downtime
Purpose: To indicate level of total unit utilization

World class: ?
Idle: Unit is mechanically operational but left idle due to any reason
Downtime: Unit is down due to maintenance or any reason of failure
WORLD CLASS PERFORMANCE
• Mechanical Availability : Min 92%
• MTBF : Min 80 hours
• Maintenance Efficiency : Min 80%
• Operating Hours/Year : Min 6500 Hours
Production Unit
• Replacement (Penggantian
- Performance
- Cost
COST
Unit Price - Resale Value

Fuel Cost
Maintenance Cost
Repair Cost
Operator
+
Owning & Operating Cost
COST
Unit Price - Resale Value

Maintenance Cost
Repair Cost
Fuel Cost
Operator
+
Owning & Operating Cost
Cost Rp/M3
MODEL 320D
RESALE VALUE OF UNIT PRICE 40%
OPERATING YEARS 5
AVAILABILITY 5950 85%
PRODUCTIVITY 50 90%
FUEL CONSUMPTION 110% Sell 5300
MAINTENANCE COST 90%
SCHEDULED REPAIR COST 110% Cost 5244
UNSCHEDULED REPAIR COST OF SCHED COST 15%
UNDERCARRIAGE COST 110% Profit 56 1%
Rp/1US$ 9100
UNIT PRICE 99,000 0.074 13%
INTEREST 5,940 0.004 1%
RESALE VALUE (39,600) (0.030) -5%
FUEL COST 401,036 0.300 52%
MAINTENANCE COST 83,934 0.063 11%
SCHEDULED REPAIR COST 153,879 0.115 20%
UNSCHEDULED REPAIR COST 23,082 0.017 3%
UNDERCARRIAGE COST 981.75 0.033 6%
TOTAL COST $/M3 0.576 100%
Rp/M3 5,244 Rp 5244 123%
Cost Rp/M3
MODEL 320D
Maint&Repair
OPERATING YEARS 5
Fuel
PRODUCTIVITY 50 100%
FUEL CONSUMPTION 100%
Availability
SCHEDULED REPAIR COST 100%
Unit Price
UNDERCARRIAGE COST 100%
Resale Value
Rp/1US$ 9100
UNIT PRICE 99,000 0.060 13%
Productivity
INTEREST 5,940 0.004 1%
RESALE VALUE (49,500) (0.030) -6%
FUEL COST 407,470 0.245 52%
SCHEDULED REPAIR COST 156,468 0.094 20%
UNSCHEDULED REPAIR COST 7,823 0.005 1%
UNDERCARRIAGE COST 897.75 0.027 6%
TOTAL COST $/M3 0.467 100%
Rp/M3 4,250 Rp 4250 100%
Cost Rp/Kwh
MODEL 3516B
RATING KW 1600
OPERATING YEARS 5
LOAD FACTOR 1200 75%
FUEL CONSUMPTION 100%
SCHEDULED REPAIR COST 100%
Rp/1US$ 10,000
UNIT PRICE 378,000 0.009 5%
INTEREST 22,680 0.0005 0%
RESALE VALUE (124,800) (0.003) -2%
FUEL COST 6,540,750 0.153 92%
SCHEDULED REPAIR COST 187,031 0.004 3% Rp 1671 100.0%
UNSCHEDULED REPAIR COST 9,352 0.0002 0.1%
ELECTRICITY COST $/Kwh 0.167 100%

Rp/Kwh 1671
UNIT PRICE
PRODUCTIVITY
AVAILABILITY
FUEL COST
REPAIR COST
MAINTENANCE COST
RESALE VALUE
(Unit price – Resale Value) + (PM + Repair + Fuel + Op)

Cost Rp/Ton = ------------------------------------------------------------------------------
Operating Hours X Productivity
Profit = (Sell Rp/Ton - Cost Rp/Ton) x Ton Production

Maintenance is
Key to the
Business Success
Production Unit
• Replacement (Penggantian
- Performance
- Cost
MAINTENANCE CONCEPT
• Objective (Sasaran):
– Ketersedian Peralatan – Untuk mencapai target
produksi, jumlah dan waktu COMPETITION
– Biaya paling rendah – biaya/jam operasi secara
keseluruhan
• Strategy:
– Longest Components Life - Vs cost to maintain
– Service at The Right Time - Vs time for production
REPAIR COST Vs OPERATING HOURS
Worse
Maintenance
Better
Repair
Maintenance
Cost
Optimum Repair Point
Operating Hours
COST/HOUR Vs OPERATING HOURS
Before Failure After Failure
Cost/Hour
Operating Hours
HIGHER LOAD = FASTER WEAR
Load
Load
85%
60%
Optimum
Repair Point
Operating Hour
Machine consists of different Components.
Each has to be managed appropriately
to achieve lowest Cost/Hour
in the entire life cycle
COMPONENT
LIFE CYCLE MANAGEMENT
COMPONENT LIFE CYCLE
MANAGEMENT
• Preventive Maintenance
• Contamination Control (CC)
• Repair Before Failure
• Condition Monitoring
• Troubleshooting and Repair
• Parts Procurement
• Maintenance Organization
• Maintenance Control System (MCS)
• Continuous Improvement
• People Development
• Change Management
• Dealer Support
PREVENTIVE MAINTENANCE
Keep wear at lowest rate by:
– Add/change lubricant
– Change/clean filter Use OMM for guideline
– Adjust wear component
– Tighten loose component
– etc
CONTAMINATION CONTROL
To keep harmful contaminants off the system
Even Particles Too Small To See

are Harmful
Cat Systems Smallest Visible Human
Clearances to the Eye Hair
2 30 40
Micron 80
CONTAMINATION CONTROL
To keep harmful contaminants off the system
REPAIR BEFORE FAILURE
Before Failure After Failure
Cost/Hour
Operating Hours
REPAIR BEFORE FAILURE
TYPICAL REPAIR COST - TURBOHARGER CAT 3516
WITH ASSUMPTION
OPTIMUM RECONDITION POINT 10,000 JAM
Reman. Cost
Condition Cost (Rp) Per hour
At Optimum Recond
Point (10,000 Hours) 20,271,000 2,027
Center Hsg Damage

(12,000 hours) 29,774,000 2,481
Total Damage
(15.000 hours) 51,000,000 3,400
At 9,000 hours 20,271,000 2,252

CONDITION MONITORING
To know condition of component’s critical part for
repair scheduling
“Anyone can run a machine to

failure Maintenance
. .Worse
. The real skill is being
Repairable to determine when is the
Better
Maintenance
Cost
BEST time to do a before failure
repair”
Operating Hours
CONDITION MONITORING
To know condition of component’s critical part for
repair scheduling
• Scheduled Oil Sampling (SOS)
• Custom Track Service
• Operational problems
• Regular Inspections
• Etc
TROUBLESHOOTING & REPAIR
• Each repair job is started with troubleshooting
– To quickly define Root Cause of the failure
– Poor troubleshooting may causes longer downtime and
expensive repair
– Wrong identification of Root Cause may causes repetitive
failure
• Use and follow procedures in Service Manual
• Apply Technical Core Skills correctly
• Work with CC and SHE
PARTS REUSABILITY
DECISION
PARTS SPECIFICATION
Use Again Max/Min
New Max/Min Permissible
Reuse for May be reused Damage.

reconditioning. for repair. Life is Must be replaced
Expected to shorter than
achieve the Target Life
the Target Life
PARTS PROCUREMENT
• Order the required parts with correct Part
Number
• No delay ordering
• Store parts on correct place and do not
open their box until time to install
MAINTENANCE ORGANIZATION
• Strategy
– Benchmarking
– Component target life and maintenance interval
– Method and technology
– Continuous improvement
• Planning
– Backlog
– Scheduling
– Procurement
• Operation
– Execution
STRATEGY PLANNING OPERATION
• What to achieve • List backlog • Perform order
• What to be done • Make schedule • Report result
• How to do it • Issue Work order
• What parts, tools • Prepare parts, etc
• What interval
• Who to do it …….
• How to do it better
OPTIMIZING EFFICIENCY QUALITY
MAINTENANCE
CONTROL SYSTEM
• Electronic or Manual
• Backlog and Scheduling
• Monitoring
• Time and Cost record
• Key Performance Indicator (KPI)
– Mechanical Availability
– Cost/Production Unit
– Etc
• Database for performance analysis and
Continuous Improvement
MCS Answers These Questions
• What Is Your Production Cost (Rp/Ton) ? Is it OK ?
– Is Cost too high or Production too low ?
– What component caused it ?
– Which machine ?
– Why ?
• What Is the Fuel Consumption ?
– Which Machine Consumed Excessively ?
• What Are Top Five Causes of Unscheduled Downtime ?
– Which machine ? Why ?
• What are Your Major/Minor Component Life ?
– Are They Reasonable ?
• Etc
CONTINUOUS IMPROVEMENT
• We can only improve what we measure (KPI)
– Lagging Indicator (end result)
– Leading Indicator (process)
• Need benchmarking
• Need database for performance analysis
• Performance = Process x Discipline
• Defect > Root Cause > Solution > Action
• Need CI Paradigm
ADVANCED TECHNOLOGY
• To comply with emission control, and trend to produce
equipment with higher productivity for User to be more
profitable, manufacturer develops
– Higher system pressure Requires changes on
maintenance practice
– Tighter clearances to utilize all values built
– More sensitive to contaminants into the machine for more
– Electronic control productive work at lower
cost
• Utilization of the new technology and the maintenance method
is critical to successfully achieve the business goals
• This requires good understanding, and PARADIGM change
CHANGE
CHANGE
• Mechanical
All of these evolutionary changes and
to Electronic
improvements
• Higher pressure have been driven by
• Customer demand to continuously improve
Less clearance
• performance
Less forgiving and reduce operating costs.
• More Incomplex
order toandremain competitive, it is
sophisticated
essential
• More for Customer to utilize all the
productive
valuereliable
• More built into
and the machines to perform
durable
• Higherproductive workless
production with at cost
lowest cost
demand
CHANGE MANAGEMENT
• The world is changing at accelerated rate
• More than 51,000 books about “change” in
amazone.com
• The Power Of A Paradigm
The Power Of
A PARADIGM
• Paradigms are the source of our thoughts
and behaviors. We can not act with integrity
outside them
• If we want to make a change, we first have
to change ourselves. And to change
ourselves effectively we have first to
change our paradigm
SELAMAT
BELAJAR
dan
BERPRESTASI

Eq. Management

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Eq. Management

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DASAR

Profit = Production - Cost

Key Performance Indicator: COST

Profit = Production - Cost

Menurut Kelompok Anda bagaimana ukuran/

Profit = Production - Cost

Key Performance Indicator: COST

Profit = Production - Cost

(Unit price – Resale Value) + (PM + Repair + Fuel + Op)

Rp/Ton x Ton Production

Idle Unsched. Maint. & Unsched

Company Working Schedule

Total Hours In 1 Year

Purpose: To indicate level of Maintenance & Repair quality

MA = 7000 X 100% = 93%

Purpose: To indicate level of Maintenance & Repair quality

Idle Unsched. Maint. & Unsched

Company Working Schedule

Total Hours In 1 Year

Purpose: To indicate quality of maintenance, repair and

Purpose: To indicate level of total unit utilization

Unit Price - Resale Value

Unit Price - Resale Value

ELECTRICITY COST $/Kwh 0.167 100%

Profit = Production - Cost

(Unit price – Resale Value) + (PM + Repair + Fuel + Op)

Profit = (Sell Rp/Ton - Cost Rp/Ton) x Ton Production

Optimum Repair Point

Before Failure After Failure

Optimum Repair Point

Even Particles Too Small To See

Before Failure After Failure

Optimum Repair Point

Center Hsg Damage

At 9,000 hours 20,271,000 2,252

“Anyone can run a machine to

Reuse for May be reused Damage.

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