HAND BOOK
DEPARTEMEN PLANT
PERIODE 2013 - 2018
1. DEFINISI
Departemen Plant PT.Madhani Talatah Nusantara sebagai bagian dalam perusahaan yang
bertanggung jawab terhadap pengelolaan asset perusahaan yaitu semua peralatan
produksi dan peralatan support.
Pengelolaan asset ini meliputi :
Program-program maintenance peralatan, perbaikan atau repair peralatan, component
atau unit overhaul, perencanaan dan analisa biaya perbaikan peralatan, proses asuransi
dari peralatan, menetapkan target availability peralatan.
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2. PLANT PROCEDURES
Procedure atau tata cara pelaksanaan divisi plant dalam menjalankan aktivitas pekerjaan
serta pembuatan laporan dalam rangka menyediakan equipment yang siap pakai untuk
proses produksi.
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Parts category backlog adalah parts hasil rekomendasi karena adanya pemeriksaan
gejala / kerusakan pada sebuah equipment dimana proses perbaikannya menunggu
waktu yang tepat dan sudah dijadwalkan .
Preventive Maintenance akan dibuatkan Work Order PM
Backlog Job akan dibuatkan Work Order Standing
Breakdown repair Job akan dibuatkan Work order Breakdown
30 menit dan diusahakan dilakukan pada saat break makan siang atau pada saat
refueling (Untuk digger), untuk model unit yang lain waktu pelaksanaannnya lebih
fleksibel.
2.1.17. Claim Process
Proses Claim wajib dibuat karena equipment mengalami kerusakan yang di sebabkan
oleh Accident atau karena adanya Warranty product.
Ada dua macam claim yaitu :
a. Claim inssurance : Claim yang ditujukan ke badan asuransi yang ditunjuk oleh
perusahaan yang diakibatkan adanya accident bukan karena bencana alam.
Proses administrasinya dilakukan oleh Asset plant admin. Dan eksekusi dan
monitoring repair dibawah tanggung jawab plant superintendent site.
Kerusakan dengan nilai kerugian di bawah nilai Detuctible insurance sesuai
agreement yang telah disepakati oleh pihak insurance, maka semua costnya
dimasukan ke beban cost accident project dengan cost code 223110.
Kerusakan dengan nilai kerugian di atas nilai Detuctible insurance, maka semua
cost akan di claim ke pihak insurance dengan cara:
1.Repair by MTN , dimana semua cost akan di claim ke pihak Insurance dengan
Cost code 003003.
2.Direct repair by insurance
Keputusan pilihan cost ini bisa dikomunikasikan ke asset plant admin. Yaitu
dengan menyerahkan : TAR (Technical Analisys Report) yang disertai estimasi
biaya repairnya atau quotation perbaikan alat.
b. Claim Dealer / Supplier : Claim ini ditujukan ke dealer atau supplier dimana kita
membeli sebuah product dari dealer/supplier tsb, claim ini diakibatkan karena
qualitas product yang kurang baik yang disebabkan oleh material defect, poor
workmanship dll .
Warranty claim kerusakan alat karena non accident/incident dibuat formnya dan
dikirim ke Plant head office dalam 1 x 24 Jam. Proses order part & claim labour
vendor dibuat oleh project.
Warranty standard equipment: 1 Tahun tanpa melihat hour meter ( CAT ; Komatsu ;
Scania ).
Extended Warranty major component : 6,000 hrs / sesuai purchase agreement.
Nissan 30,000 KM atau 1 Tahun mana yang tercapai lebih dulu.
Hitachi 3,000 hrs , sedangkan additional power train warranty-nya 6,000 hrs atau 24
Bulan mana yang tercapai lebih dulu.
Warranty karena alasan “good will“ atau marketing decision akan dinegosiasikan
dan difollow up Head office.
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seperti lubricating, kapasitas vessel, kapasitas bucket, electrical, tyre dll, harus
dikonsultasikan ke dealer/supplier. Proses modifikasi harus sepengetahuan Plant
Manager. Khusus perubahan dengan mengubah fungsi suatu equipment harus
disetujui oleh Director.
2.1.19. Unschedule job :
a. Kerusakan yang terjadi secara tiba-tiba pada suatu equipment yang disebabkan
karena tidak berfungsinya suatu component atau system.
b. Operator menginformasikan kerusakan alatnya ke Plant melalui dispatcher.
c. Plant supervisor akan mengevaluasi kerusakan dan melaporkan ke dispatcher
tentang jenis kerusakan, hourmeter, lokasi perbaikan, estimasi lama pekerjaan.
d. Dispatcher akan meminta Mine Supervisor untuk menyiapkan tempat yang aman
untuk perbaikan di lapangan atas permintaan dari Plant Supervisor.
e. Selanjutnya kerusakan bisa dikerjakan setelah mendapat info dari Mine
Supervisor tentang tempat yang aman untuk melaksanakan pekerjaan tersebut.
f. Setelah pekerjaan selesai, Plant supervisor/foreman membuat laporan ke
Maintenance Planner dan langsung menutup jam breakdown ke dispatcher dan
melengkapi work order dengan downtime hours dan activitynya.
g. Kerusakan yang akan ditangani oleh Dealer harus dikoordinasikan dengan Plant
Superintendent atau Plant Supervisor terlebih dahulu.
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- Meningkatkan kebersihan unit & terhindar dari kerusakan akibat kotoran , lumpur,
debu serta bahan-bahan yang mudah terbakar.
- Meningkatkan qualitas pemeriksaan unit.
- Meningkatkan qualitas proses pekerjaan repair & maintenance.
- Meningkatkan kenyamanan dalam pengoperasian unit.
2.1.22. Leadtime Standard GOH & Midlife Overhaul :
Divisi Plant telah membuat standard lamanya pekerjaan GOH ataupun Midlife
sebagai acuan untuk membuat time frame / schedule pekerjaan serta target
availability.
Berikut adalah Standard Leadtime yang dimaksud:
Leadtime Standard GOH Jika semua menggunakan PEX/COMEX/PTA:
-Big machine : 14 Days
-Small Machine : 10 Days
Leadtime Standard GOH jika tidak menggunakan PEX/COMEX/PTA:
-Big Machine : 30 Days
-Small Machine : 21 Days
Leadtime Standard Midlife Ovh dengan menggunakan PEX/COMEX/PTA:
-Big machine : 6 Days
-Small Machine : 4 Days
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Operating Hours
MTBS (Hour)=
Number of shutdown in the period
Dengan catatan sbb :
- Shutdown adalah kajadian suatu machine dalam kondisi out of service
- Shutdown mencakup semua jenis maintenance dan aktivitas perbaikan kecuali:
daily lubes, refueling, inspeksi selama proses daily lube & refueling.
- Pencapaian MTBS > 70 Hours maka dinyatakan GOOD
- Pencapaian MTBS < 50 Hours maka dinyatakan BAD
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4. MONTHLY REPORT.
Plant divisi mewajibkan setiap project aktif membuat monthly report yang berisi laporan
program plant selama 1 bulan termasuk penghitungan actual availability equipment serta
KPI lainnya. Pembuatan monthly report di site menjadi tanggung jawab maintenance
planner kemudian dicheck oleh plant superintendent dan dilaporkan ke project manager
dengan tembusan ke plant manager, All plant head office dan departemen terkait di site
maupun di head office.
6.1. Forecast Availability (Planning)
Forecast monthly dibuat oleh maintenance planner atas persetujuan
superintendent/supervisor untuk mengetahui target PA yang ditawarkan ke produksi
pada setiap equipment untuk periode tertentu.
Forecast Monthly di serahkan ke engineering, PM dan plant HO paling lambat tgl 23
bulan sebelumnya.
Forecast 3 Monthly juga dibutuhkan oleh technical dept. Paling lambat diserahkan
setiap bulan pertama tanggal 23 untuk 3 monthly berikutnya.
Forecast Weekly juga diperlukan, planner membuat planning weekly ini berdasarkan
forecast monthly yang telah direncanakan.
Penghitungan Forecast mempunyai standard sbb :
a. Plan Maintenance
Yaitu jumlah total jam maintenance schedule untuk sebuah equipment selama 1
bulan, bisa diketahui dari planning service yang sudah dibuat schedulenya.
Sehingga rencana jam total yang dibutuhkan sebuah equipment dapat kita hitung
per unit selama 1 bulan.
Greasing dan Daily Maintenance :
- HD, DT, ADT, Dozer, Grader, Compactor : 5 jam/bulan
- Excavator : 15 jam/bulan
- Lighting Tower/ Light vehicle/Pump/genset/welding machine : 3 jam/bulan.
Plan Service : Untuk Big fleet
Service 250 hrs : 1 jam 2 Jam
Service 500 hrs : 2 jam 4 Jam
Service 1000 hrs : 3 jam 6 Jam
Service 2000 hrs : 4 jam 8 Jam
Schedule Repair :
Midlife/overhaul, Pekerjaan backlog, Modifikasi internal/external.
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Note : Pada saat suatu equipment dilakukan Midlife ataupun overhaul, berarti
rencana breakdown service 2000 dan greasing selama midlife / overhaul di
hilangkan dari forecast down , hal ini akan mempengaruhi kenaikan forecast MA.
b. Breakdown time Unschedule Estimate
Dalam penghitungan forecast, PT. Madhani Talatah Nusantara menetapkan
standard unscheduled down :
- Unit HM 0 – 2,000 hrs : max 1 % per bulan
- Unit HM 2,000 – 6,000 hrs : max 3 % per bulan
- Unit HM 6,000 – 12,000 hrs : max 5 % per bulan
- Unit HM 12,000 hrs- up : max 7 % per bulan
c. Total Possible Working Hours per month
Yaitu jumlah jam dalam 1 bulan ( 24 jam x jumlah hari dalam bulan tsb )
d. Total Down
Total down adalah jumlah jam rencana maintenance ditambah jumlah jam
rencana breakdown time unscheduled estimate
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7.21. Mechanic
Mechanic berfungsi sebagai pelaksana proses pekerjaan mechanical yang mempunyai
kompetensi dan bekerja secara team work.
a. Bertanggung jawab kepada Foreman Mechanik.
b. Melaksanakan pemeliharaan dan perbaikan peralatan dengan benar sesuai dengan
prosedur dan standar manual.
c. Melaksanakan order sparepart dan consumable goods yang diperlukan dalam
pelaksanaan perawatan maupun perbaikan peralatan.
d. Melaksanakan trouble shooting dan pekerjaaan tehnis lainnya untuk mempercepat
leadtime repair agar unit bisa segera beroperasi kembali.
e. Bertanggung jawab terhadap pemeliharan kebersihan & kelengkapan Tools,
tempat kerja dan fasilitas workshop.
f. Mencatat & membuat laporan daily kegiatan pelaksanaan pemeliharaan dan
perbaikan peralatan dalam form Move Time Card.
g. Membuat laporan analisa tehnis dari problem pada peralatan yang berupa
Technical analisis Report setiap bulan minimal 2x.
h. Membuat improvement proposal untuk perbaikan tools & perlengkapan kerja,
metode kerja, sarana kerja, modifikasi peralatan setiap bulan minimal 1x.
7.22. Electrician
Electrician berfungsi sebagai pelaksana proses pekerjaan electrical yang mempunyai
kompetensi dan bekerja secara team work.
a. Bertanggung jawab kepada Foreman Electrician.
b. Melaksanakan pemeliharaan dan perbaikan peralatan dengan benar sesuai dengan
prosedur dan standar manual.
c. Melaksanakan order sparepart dan consumable goods yang diperlukan dalam
pelaksanaan perawatan maupun perbaikan peralatan.
d. Melaksanakan trouble shooting dan pekerjaaan tehnis lainnya untuk mempercepat
leadtime repair agar unit bisa segera beroperasi kembali.
e. Bertanggung jawab terhadap pemeliharan kebersihan & kelengkapan Tools,
tempat kerja dan fasilitas workshop.
f. Mencatat & membuat laporan daily kegiatan pelaksanaan pemeliharaan dan
perbaikan peralatan dalam form Move Time Card.
g. Membuat laporan analisa tehnis dari problem pada peralatan yang berupa
Technical analisis Report setiap bulan minimal 2x.
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7.23.Tyreman
Tyreman berfungsi sebagai pelaksana pekerjaan tyre yang mempunyai kompetensi
dan bekerja secara team work.
a. Bertanggung jawab kepada Foreman Tyre.
b. Melaksanakan pemeliharaan dan perbaikan tyre suatu peralatan dengan benar
sesuai dengan prosedur dan standar manual.
c. Melaksanakan order sparepart dan consumable goods yang diperlukan dalam
pelaksanaan perawatan maupun perbaikan peralatan.
d. Bertanggung jawab terhadap pemeliharan kebersihan & kelengkapan Tools,
tempat kerja dan fasilitas workshop.
e. Mencatat & membuat laporan daily kegiatan pelaksanaan pemeliharaan dan
perbaikan tyre suatu peralatan dalam form Move Time Card.
f. Membuat laporan analisa tehnis dari problem tyre pada peralatan yang berupa
Technical Damage Report setiap bulan minimal 2x.
g. Membuat improvement proposal untuk perbaikan tools & perlengkapan kerja,
metode kerja, sarana kerja, modifikasi peralatan setiap bulan minimal 1x.
7.24.Welder
Welder berfungsi sebagai pelaksana pekerjaan pengelasan atau fabrikasi yang
mempunyai kompetensi dan bekerja secara team work.
a. Bertanggung jawab kepada Foreman Welder.
b. Melaksanakan pengelasan atau fabrikasi dengan benar sesuai dengan prosedur
dan standar manual.
c. Melaksanakan order consumable goods yang diperlukan dalam pelaksanaan
pengelasan atau fabrikasi.
d. Bertanggung jawab terhadap pemeliharan kebersihan & kelengkapan Tools,
tempat kerja dan fasilitas workshop.
e. Mencatat & membuat laporan daily kegiatan pengelasan dan fabrikasi dalam
form Move Time Card.
f. Membuat improvement proposal untuk perbaikan tools & perlengkapan kerja,
metode kerja, sarana kerja, modifikasi peralatan setiap bulan minimal 1x
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7.25.Planner Clerk
Sebagai dispatcher plant untuk mencatat data unit breakdown dan RFU serta bekerja
sama dengan
a. Bertanggung Jawab ke Maintenance Planner (project).
b. Memasukkan data-data pendukung dalam proses perencanaan
maintenance yang dibuat oleh Maintenance Planner Project.
c. Membantu secara kolektif administrasi ( cuti,lembur..dll ) semua personal
plant yang berkenaan dengan HRD dengan persetujuan plant superintendent yang
selanjutnya proses tersebut dilakukan oleh HRD project.
d. Sebagai dispatcher plant untuk mencatat data unit breakdown dan RFU
serta bekerja sama dengan dispatcher production.
e. Membantu membuat monthly report plant project.
6. PENUTUP
Handbook plant ini telah diperiksa dan disetujui oleh Senior Plant Manager serta telah
didiskusikan dengan Plant Superintendent di head office maupun di project.
Standarisasi form-form akan disesuaikan dengan perkembangan equipment yang dimiliki
PT.Madhani Talatah Nusantara dan masih dimungkinkan untuk direvisi dan ditambah sesuai
kebutuhan di waktu yang akan datang.
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9. LAMPIRAN
9.1. FLOW CHART PLANT DEPARTMENT PROCEDURE.
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POOR :
FAIR :
GOOD :
VERY GOOD :
SAFETY DEVICE Yes No
Radio Comm + PTT+Antena :
APAR :
REMARKS DC Conventer : REMARKS
Fatique Alarm :
FSS/Fire Supression :
LOTO :
DISTRIBUTION DISTRIBUTION
JKT FA ADM. RECEIVING PROJ. DESPATCH PROJECT JKT FA ADM. RECEIVING PROJECT DESPATCH PROJECT
COMMENTS :
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Halaman 1 dari 1
Complete and Distribute this Form at any point of origin of one of the above AUTHORISATION No. :
DATE OF DISPOSE :
INSURANCE CANCELLED LOG BOOK WITHDRAWN TO : REGISTRATION CANCELLED / TRANSFERRED SPECIAL TOOLS AND MANUALS SALE PRICE
WITHDRAWN TO :
DATE OF VARIATION :
Log Book Entered : Insurance Co. Advised : Motor Registry Advised : Additional Cost :
(Give full details and Serial Numbers)
FORM REQUESTED BY : ANDREA SIGIT ............................................... DATE : ……………………… TRANSACTION AUTHORISED BY : DWI HARTANTO....................................... DATE : …………………….
'CHECKED BY : PAUL LUDLOW ............................................................ DATE : ………………..……. APPROVED BY : DAVID RONALDSON……..............................................…… DATE : ………………………
DISTRIBUTION
Original - HEAD OFFICE JAKARTA PLANT SECTION Purchase Date
Copy - ACCOUNTING Purchase Price
WDV at time or sale
Sale Gain / (Loss)
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1
WO Number
2
3
Date : _____________________
Hour Meters
Hour Meters
Problem : Problem :
REASON :
___________________
Mechanic / FM / Spv Plant Supt. Project Manager Maint. Planner
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UKURAN BAN :
MERK : SERIAL NO. :
PATTERN :
PRESSURE : PROJECT :
OTD :
PASANG LEPAS
UNIT ID # POS UMUR TUR % ALASAN BAN DILEPAS
TANGGAL SMU RTD 1 RTD 2 TANGGAL SMU RTD 1 RTD 2
TOTAL LIFE
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PROJECT :
TYRE SIZE :
DATE :
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TDR no:
PROJECT DATA MANPOWER DATA
ENVIRONMENTAL DATA
TRUCK DATA
TYRE DATA
DAMAGE DATA
22 Type of Damage: Side Wall Cut ( Dinding Putus ) Shulder Separation ( Bahu Terkelupas )
Tread Cut ( Telapak Putus ) Bead Broken ( Bibir Ban Rusak )
Shoulder Cut ( Bahu Putus ) Impact Break ( Meledak )
Side Wall Separation ( Dinding Gembung ) Run Flat ( Kempes Dibawa Jalan )
Tread Separation ( Telapak Terkelupas ) Flat Inner Tube ( Ban Dalam Bocor )
Run Out ( Gundul ) Rim Broken ( Rim Rusak )
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WO :
Fax : 021-29661511
To : TAR No. :
Address : Date :
Attn :
Telp : Delivery Date :
CC :
Model Make : Model Type : Kilometers :
Problem/Issue :
Reason of Failure :
Component List :
Estimasi Cost :
Parts Number Description QTY
TOTAL
PPN 10%
Grand Total
Picture :
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WO :
Fax : 021-29661511
To : WCR No. :
Address : Date :
Attn :
Telp : Delivery Date :
CC :
Model Make : Model Type : Kilometers :
Symptom :
Reason of Failure :
Action taken:
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Component List :
Description Parts No. Qty
Pleasen fill data Please fill data Please fill data
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Halaman 1 dari 2
JOB DESCRIPTION (DETAILINSTRUCTIONS) DIMENSI (GAMBAR SESUAI UKURAN YANG DIKEHENDAKI DAN BISA DITAMBAHKAN KE CONTINUOUS FORM)
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EQUIPMENT :
Equipment Number
Equipment Model
Equipment Serial Number
Location / Site
Machine Breakdown Yes No
Hour Meter
COMPONENT REQUESTED :
Component Name Component Part Number
SCOPE OF WORK
Scheduled Recondition Other ……………………..
Unscheduled Recondition
IDENTIFICATION
Detail problem :
Request By :
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MACHINE ENGINE
JOB DESCRIPTION
MODEL S/N C/ N SMR MODEL S/N
WO
LEAD TIME MONITORING GRAPH DATE
HRS MAN % DAYS Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10 Day 11 Day 12
NO. JOB DECRIPTION
WORK HOURS TAGE Date
100%
1
3 P
R
4 O
C
5
E
6 N
T
7 A
8
G
E
9
G
10
R
11 A
P
12 H
13
dst
0%
GRAND TOTAL 0 0
SECTION
MAN HOURS
NO M/Power Dayshift M/Power Nightshift
1
DELAYED
2
3 PARTS ORDER
4 (NORMAL)
5
RE-ORDER
6
DELAYED CODE A= PENDING PARTS G= WAITING COMP FR OTHER SECT. .........................................., .................. 20...
B= PENDING MAN POWER H= REDO IN PROCESS APPROVED BY, PREPARED BY,
C= TOOLS NOT AVAILABLE I= REDO COMP LOCAL WHEN RECEIVING
D=PENDING TEST & PPM J= CANNIBAL
E= WAITING LOCAL MADE COMP. K= WAIT FOR REPAIR
F= DOING ANOTHER JOB L= HOLIDAY PLANT SUPERINTENDENT MAINTENANCE PLANNER
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Halam an 1 dari 1
( ) ( )
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WO No Rece ived by, Sent by, Approve d by, Approved By Orde red by,
POF Supp lie r / Ve ndo r Wa re house Spv / Frm QA & Te c hnic a l Supt. Pla nt Supe rinte nde nt Spv / Fo re ma n Pla nt
Da te
Unit Mode l
Unit Code
Vendor/ Supplier
Addre ss
Attn.
Telp / Fa x
Work Orde r For
Fa bric a tion Welding Reboring Grinding ( ) ( ) ( ) ( ) ( )
Asse mbly Pa inting Rechroming Others Da te : Da te : Da te : Da te : Da te :
JOB DESCRIPTION (DETAILINSTRUCTIONS) DIMENSI (GAMBAR SESUAI UKURAN YANG DIKEHENDAKI DAN BISA DITAMBAHKAN KE CONTINUOUS FORM)
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Workorder Desc
Operation Desc
Planning Notes
Operation Instructions
Labour Assigned
Actual
Employee Labour Activity Workgroup Qty JSA Read Start Time Instructions Planned Hrs
Hrs
Feedback:
Completion Checks:
Name
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Running Breakdown
Approval By : Allocated to :
MTN - 001S - ORG
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9.2.19. CER-GOH
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In Budget
TITLE: UNIT NO:
PLANT DESCRIPTION:
ANALYSIS
Total Real
After Tax
Option Description Cashflows NPV (US$) Comments
1
2
Recommended Option:
#VALUE!
C. ACCOUNTING
ACCOUNT NUM BER:
DEPRECIATION
EST. EFFECTIFE LIFE REMAINING (HRS) EST. RESIDUAL VALUE
D. APPROVAL
REQUESTED BY SIGNATURE DATE
# Accountant to verify all information inserted including tax and book values, discount rate, interest rate, etc
* Finance - confirms that finance is available for option recommended
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Tanda Tangan TINJAUAN TERHADAP IDE : TINJAUAN TERHADAP USAHA & HASIL IMPROVEMENT :
Pembuat Ide Proposal bersifat : Evaluator Penilaian Rata2 Nilai Komentar Project Mgr / Mgr Penghargaan
Menciptakan Tanda Tangan a. Nilai Usaha Ya
b. Nilai Manfaat
Meningkatkan standar Nama
Tanda Tangan
Tanggal Tidak
Mencontoh Follow Up Ide Dilaksanakan Dilaksanakan Ket. Nilai : 1 : Kurang sekali 3. Cukup 5. Baik Sekali
Improvement Ditolak Ditolak 2 : Kurang 4. Baik
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9.2.21. CER-INV.
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CERINV Number:
Date:
Project Name:
Title: Project Code
In Budget
Out of Budget
B. Option Summary:
A ssumptions:
Taxation rate
Tax Depreciation Rate
Annual real discount rate
Monthly real discount rate
1 0 0 NA NA NA NA
2 0 0 NA NA NA NA
3 0 0 NA NA NA NA
Recommended Option:
See attached Commentary for justification and cash flow considerations
C. Accounting
Account Number
Depreciation
Est Effective Life: Est. Residual Value:
Depreciation Rate:
D. Approval
REQUESTED BY Agus Santoso SIGNATURE DATE
Title Operation Manager
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9.2.22. CER-MIN.
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CERMIN Number:
A. REQUEST DETAILS:
Date:
PROJECT NAME: PROJECT CODE:
Asset: X Additional
Replacement Replacment Unit Number(s):
CLASS MAKE / MODEL SUPPLIER QTY COST PRICE TOTAL VAT TOTAL PRICE
$ - $ - $ -
$ - $ - $ -
JUSTIFICATION/RECOMMENDATION
B. PAYMENT
TERMS OF PAYMENT CASH N30 LEASING ASSET NUMBER #REF!
INSTALLMENT PERIOD
INSURANCE INTEREST
C. ACCOUNTING
ACCOUNT NUMBER:
DEPRECIATION
EST. EFFECTIFE LIFE EST. RESIDUAL VALUE
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EQUIPMENT CODE
MAKE : YEAR :
MODEL : HOUR METER :
SERIAL NUMBER : ENGINE TYPE :
EQUIPMENT TYPE :
EXCAVATORS HAULER / TRUCK MOTOR GRADER BULLDOZER OTHERS
Hoses YES NO
Cylinders YES NO
Pipings YES NO
Suspension Cylinder YES NO (Dump Truck Only)
Last Component Change Out :
HYDRAULIK PUMP NO.... Date: HM:
HYDRAULIK PUMP NO.... Date: HM:
HYDRAULIK PUMP NO.... Date: HM:
HYDRAULIK CYLINDER ...... Date: HM:
HYDRAULIK CYLINDER ...... Date: HM:
HYDRAULIK CYLINDER ...... Date: HM:
Describe any abnormal on Hydraulik system :
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1. Maintenance Management
-Perawatan Area Workshop beserta kelengkapan/peralatannnya
1.1 Ada penanggung jawab keselamatan dan kesehatan kerja di area workshop
1.2 Memil iki SOP/JSA/IK pemeriksaan dan pemeliharaan area kerja/peralatan kerja
1.3 Memil iki jadwal Inspeksi dan pemeliharaan area kerja serta peralatan kerja
1.4 Ada petugas yang ditunjuk untuk pelaksanaan i nspeksi dan pemeliharaan
1.5 Memil iki daftar peralatan yang harus dilakukan pemeri ksaan / perawatan
-Sikap dan Cara Kerja Karyawan
1.6 Karyawan memili ki sikap yang baik dan sopan
1.7 Disiplin dal am menggunakan APD
1.8 Bekerja dengan menggunakan referensi kerja : SOP/IK/JSA
1.9 Bekerja dengan posi si yang kokoh, aman dan ergonomis
1.10 Merokok di tempat khusus yang diperbolehkan di dalam lingkungan workshop
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Model Unit Code Unit Nomor Seri Unit Hour Meter Shift Tanggal
SAFETY FIRST Lama waktu tidur …….… Jam Kondisi badan Sehat/tidak sehat
(Coret yang tidak perlu)
PARKIR UNIT DI TEMPAT YANG RATA, TURUNKAN DUMP BODY , POSISIKAN
CONTROL LEVER KONDISI NETRAL DAN TERKUNCI
KONDISI
A PEMERIKSAAN UMUM ( WALK AROUND CHECK ) KETERANGAN
BAIK TIDAK
1 Periksa kondisi di sekitar engine (kebocoran oli, fuel, air, dll).
2 Periksa kondisi di sekitar radiator/oil cooler (kebocoran air, dll).
3 Periksa kondisi di sekitar transmisi assy (kebocoran oli, dll).
4 Periksa kondisi front & rear axle assy (kebocoran oli, retak, dll).
5 Periksa kondisi steering orbitroll / valve (kebocoran oli, dll).
6 Periksa kondisi suspension cylinder (kebocoran oli, dll).
7 Periksa kondisi all cylinder & hoses (kebocoran oli, dll).
8 Periksa kondisi ban & rim (kempes, pecah, bolt kendor, dll).
9 Periksa kondisi dump body / attachment (aus, sobek, dll).
10 Periksa kondisi chassis, frame, cover (aus, penyok, dll).
11 Periksa kondisi fisik cabin (penyok, kaca buram, dll ).
12 Periksa kondisi operator seat & safety belt (bisa disetel, dll).
13 Periksa kondisi electrical system (kabel lepas, lampu pecah dll).
14 Periksa kondisi tabung APAR (tersedia & gauge tidak rusak).
15 Periksa kondisi kaca spion ( harus lengkap & baik )
KONDISI
B PEMERIKSAAN SEBELUM ENGINE HIDUP KETERANGAN
BAIK TIDAK
1 Periksa level air pendingin di reservoir tank
2 Periksa level oli engine pada dipstick di engine block.
3 Periksa level oli transmission
4 Periksa level oli brake system / brake cooling
5 Periksa level oli steering & hydraulik system
6 Periksa level fuel
7 Periksa fungsi buzzer & caution lamp di monitor panel
8 Periksa fungsi klakson / horn
9 Periksa kebuntuan air cleaner di dust indicator
10 Periksa kondisi water separator, buang air serta endapan.
KONDISI
C PEMERIKSAAN SETELAH ENGINE HIDUP BAIK TIDAK
KETERANGAN
1 Periksa tekanan oli engine di monitor panel
2 Periksa suhu air pendingin engine di monitor panel
3 Periksa fungsi emergency stop switch (jika dilengkapi).
4 Periksa fungsi radio komunikasi.
5 Periksa fungsi lampu rotary & lampu kerja
6 Periksa fungsi fatigue warning alarm
7 Periksa fungsi brake system
8 Periksa fungsi steering system.
9 Periksa fungsi dump / hoist / attachment.
10 Periksa fungsi air conditioning system
NAMA NIK TANDA TANGAN Kategori Tingkat Bahaya
Jika terjadi ketidaknormalan, unit bisa dioperasikan
OPERATOR = sampai dengan dilaksanakannya perbaikan atas
(*1) kerusakan yang terjadi.
Jika terjadi ketidaknormalan, engine bisa
PENGAWAS
OPERATOR = dihidupkan untuk dilakukan pemeriksaan lebih
(*2) lanjut tetapi unit dilarang untuk dioperasikan.
MECHANIK / Jika terjadi ketidaknormalan, engine dilarang untuk
PENGAWAS =
dihidupkan / kalau engine dalam keadaan hidup
MECHANIK (*3) maka harus segera dimatikan.
Catatan :
*1.Operator wajib mengisi dan menandatangani form P2H ini di awal shift sebelum unit dioperasikan dan diserahkan kepada pengawas.
*2.Pengawas operator wajib menandatangani form P2H ini di awal shifts.
*3.Mechanik yang telah ditunjuk atau pengawas mechanik wajib menandatangani form P2H apabila telah melakukan pemeriksaan atas unit yang
mengalami kerusakan dan merekomendasikan untuk bisa dioperasikan.
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Model Unit Code Unit Nomor Seri Unit Hour Meter Shift Tanggal
SAFETY FIRST Lama waktu tidur …….… Jam Kondisi badan Sehat/tidak sehat
(Coret yang tidak perlu)
PARKIR UNIT DI TEMPAT YANG RATA, TURUNKAN DUMP BODY , POSISIKAN
CONTROL LEVER KONDISI NETRAL DAN TERKUNCI
KONDISI
A PEMERIKSAAN UMUM ( WALK AROUND CHECK ) KETERANGAN
BAIK TIDAK
1 Periksa kondisi di sekitar engine (kebocoran oli, fuel, air, dll).
2 Periksa kondisi di sekitar radiator/oil cooler (kebocoran air, dll).
3 Periksa kondisi di sekitar transmisi assy (kebocoran oli, dll).
4 Periksa kondisi front & rear axle assy (kebocoran oli, retak, dll).
5 Periksa kondisi steering orbitroll / valve (kebocoran oli, dll).
6 Periksa kondisi suspension cylinder (kebocoran oli, dll).
7 Periksa kondisi all cylinder & hoses (kebocoran oli, dll).
8 Periksa kondisi ban & rim (kempes, pecah, bolt kendor, dll).
9 Periksa kondisi dump body / attachment (aus, sobek, dll).
10 Periksa kondisi chassis, frame, cover (aus, penyok, dll).
11 Periksa kondisi fisik cabin (penyok, kaca buram, dll ).
12 Periksa kondisi operator seat & safety belt (bisa disetel, dll).
13 Periksa kondisi electrical system (kabel lepas, lampu pecah dll).
14 Periksa kondisi tabung APAR (tersedia & gauge tidak rusak).
15 Periksa kondisi kaca spion ( harus lengkap & baik )
KONDISI
B PEMERIKSAAN SEBELUM ENGINE HIDUP BAIK TIDAK
KETERANGAN
1 Periksa level air pendingin di reservoir tank
2 Periksa level oli engine pada dipstick di engine block.
3 Periksa level oli transmission
4 Periksa level oli brake system / brake cooling
5 Periksa level oli steering & hydraulik system
6 Periksa level fuel
7 Periksa fungsi buzzer & caution lamp di monitor panel
8 Periksa fungsi klakson / horn
9 Periksa kebuntuan air cleaner di dust indicator
10 Periksa kondisi water separator, buang air serta endapan.
KONDISI
C PEMERIKSAAN SETELAH ENGINE HIDUP KETERANGAN
BAIK TIDAK
1 Periksa tekanan oli engine di monitor panel
2 Periksa suhu air pendingin engine di monitor panel
3 Periksa fungsi emergency stop switch (jika dilengkapi).
4 Periksa fungsi radio komunikasi.
5 Periksa fungsi lampu rotary & lampu kerja
6 Periksa fungsi fatigue warning alarm
7 Periksa fungsi brake system
8 Periksa fungsi steering system.
9 Periksa fungsi dump / hoist / attachment.
10 Periksa fungsi air conditioning system
NAMA NIK TANDA TANGAN Kategori Tingkat Bahaya
Jika terjadi ketidaknormalan, unit bisa dioperasikan
OPERATOR = sampai dengan dilaksanakannya perbaikan atas
(*1) kerusakan yang terjadi.
Jika terjadi ketidaknormalan, engine bisa
PENGAWAS
OPERATOR = dihidupkan untuk dilakukan pemeriksaan lebih
(*2) lanjut tetapi unit dilarang untuk dioperasikan.
MECHANIK / Jika terjadi ketidaknormalan, engine dilarang untuk
PENGAWAS =
dihidupkan / kalau engine dalam keadaan hidup
MECHANIK (*3) maka harus segera dimatikan.
Catatan :
*1.Operator wajib mengisi dan menandatangani form P2H ini di awal shift sebelum unit dioperasikan dan diserahkan kepada pengawas.
*2.Pengawas operator wajib menandatangani form P2H ini di awal shifts.
*3.Mechanik yang telah ditunjuk atau pengawas mechanik wajib menandatangani form P2H apabila telah melakukan pemeriksaan atas unit yang
mengalami kerusakan dan merekomendasikan untuk bisa dioperasikan.
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Halaman 1 dari 1
Despatching Receiving
Reg AMF Asset Description Status
Oraganization Physical Loc Oraganization Physical Loc
REMARKS
Recommended by GM Minning,
Signed Date
Acknowledge by GM Plant ,
Signed Date
Approve by Director,
Signed Date
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CONDITION
Uraian Pekerjaan - Job Description
OK NOT OK
Bersihkan Unit Sebelum di Inspeksi - Steam clean before Inspection
SAFETY DEVICES
Periksa semua petunjuk safety tersedia & jelas (Check if safety sign / pinch point sticker are fitted & clear)
Periksa pemadam api/ apar 6 kg, ganti jika diperlukan (Check fire extinguisher 6kg, replace if required)
Periksa kondisi alat pemadam otomatis/jika tersedia(Check condition of Fire Suppression System/if available)
Periksa tangga untuk naik operator (Inspect ladder for damaged)
Periksa semua tutup & pengaman ada dan lengkap (Check that all guards and covers are in place and secure)
Periksa fatique alarm system bekerja & dalam kondisi baik (Check fatigue alarm system condition & operation)
Periksa isolation swicth / LOTO bekerja dengan baik (Check isolation switch operation in good condition)
Periksa fungsi lampu rotary (Check rotary lamp function)
Periksa radio komunikasi bekerja & dalam kondisi yg baik (Check 2 way radio condition & operation)
Periksa fungsi alarm mundur/ berjalan (Check back / travel alarm function)
Periksa daerah mesin/transmissi yang panas dari sampah (Inspect engine/transmission hot areas for rags)
Pengetesan fungsi saklar untuk matikan mesin dalam kondisi darurat (engine emergency stop switch testing)
ENGINE & RELATED PARTS
Periksa kebocoran air di sekitar mesin (Check engine for water leaks)
Periksa kebocoran oli sekitar mesin (Check for oil leaks around engine)
Periksa kebocoran sistem bahan bakar (Check for fuel system leaks)
Periksa kondisi hose dan clamp (Check for conditions of hoses and clamps, replace when required)
Periksa kekencangan dan kebocoran fuel line clamp (Check Fuel Line Clamp for tightness & Leaks)
Periksa ketegangan kondisi V-belt (Check tension and condition of v-belt)
Periksa kebocoran air core dan tutup radiator (Inspect radiator core & cap for leaks)
Periksa bearing kipas dan pulley yang longgar (Inspect fan and pulley bearings for looseness)
Periksa kekencangan baut kedudukan mesin (Check engine mount bolts are tight)
Periksa sambungan sistem knalpot yang bocor (Inspect exhaust system joints for leaks)
Periksa sistem udara masuk yang bocor (Inspect air induction system for leaks)
Periksa level indikator saringan udara (Check air filter indicator level)
POWER TRAIN & BRAKE SYSTEM
Periksa transmisi & t/converter untuk kebocoran oli (Check transmission & t/converter for oil leaks)
Periksa differential/ final drive/ wheel hub untuk kebocoran oli (Check Diff/F. Drive/wheel hubs for oil leaks)
Periksa kondisi damper; PTO; propeller shaft / joint (Check condition damper; PTO; propeller shaft)
Periksa kencangkan baut kedudukan transmisi (Check trans mount bolts are tight)
Periksa semua fitting dan clamp terikat kuat ( Check for all fitting and clamps are tightness)
Periksa kebocoran sekitar rem depan dan belakang (Check all brakes for oil leaks)
Periksa kebocoran/aus semua hose rem (Inspect hoses and connection brake system for leaks and worn)
Periksa keausan disc/pad rem depan/parkir (Check wear of disc, pad front/parking brake)
Periksa Kebocoran oli dari floating seal (Check Oil Leaking From Floating Seal)
9.2.28. Comissioning.
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Machine No. : ................................... Machine Model : ................................. Service Meter Unit : ..................................
Machine Brand : ................................... Serial Number : .................................
EQUIPMENT TYPE : Keterangan: Isi (V) pada kotak sesuai type unit, tuliskan type unit jika memilih lainnya = ................................
EXCAVATORS BULLDOZER DRILLING MTR GRADER W/ LOADER ALL TRUCKS L/VEHICLE LAINNYA
DIPERIKSA OLEH DIPERIKSA OLEH
ITEM CHECK CONTENT (PROYEK PENGIRIM) (PROYEK PENERIMA)
Baik Tidak Baik Baik Tidak baik
Periksa kondisi di sekitar engine (kebocoran oli, fuel, air, gas, dll).
Periksa kondisi di sekitar radiator (kebocoran air, banyak kotoran, dll).
Periksa kondisi transmission/ power train (kebocoran oli, dll). * Wheel type & dozer
Periksa kondisi generator / alternator . *Genset, lighting plant
Periksa kondisi water pump/ pump end (kebocoran air, dll).* dew atering pum p
Periksa kondisi PTO/ pump drive gear box/ splitter box (kebocoran oli, dll)
Periksa kondisi final drive, travel/propel motor (kebocoran oli, dll). *track type
Periksa kondisi swing machinery & swing motor. *(Excavator/digger)
Periksa kondisi axle, differential, f/drive, tandem (kebocoran oli, dll). *w heel type
Periksa kondisi component undercarriage (aus, bolt kendor dll). *track type
Periksa kondisi suspension depan/belakang (kebocoran oil, level). *w heel type
Periksa kondisi ban & rim (kempes, sobek, pecah, bolt kendor, dll). *w heel type
Periksa kondisi steering gear box / orbitroll valve ( kebocoran oli, dll ). *w heel type
Periksa kondisi brake system (kebocoran oli, dll). *w heel type
Periksa kondisi air compressor & air system.*w heel type & drilling
Periksa kondisi hydraulik pump, motor, system ( kebocoran oli, dll ).
Periksa kondisi hydraulik cylinder & hoses ( kebocoran oli, pecah, dll ).
GENERAL CHECK
Page | 86
Hand Book
Plant Department 2013-2018 5Thinks of Plant :Safety, Planning, Fast,
Good & Saving
PT. MADHANI TALATAH NUSANTARA
Construction and Mining Contractors
Page | 87
Hand Book
Plant Department 2013-2018 5Thinks of Plant :Safety, Planning, Fast,
Good & Saving