12.1. Maintenance Budgeting - PT GNA

MODUL MAINTENANCE BUDGETING
MAINTENANCE BUDGETING
PT GENTA NUSA ARSANA 1

www.gentanusaarsana.com
BIODATA
Nama :
Alamat :
Telepon :
Nomor ID :
Instansi :
………………………. , / /
( ……………………………)

Puji syukur kami ucapkan kepada Tuhan Yang Maha Kuasa, atas segala
rahmat-Nya, sehingga Modul Maintenance Budgeting ini telah
terselesaikan dengan baik.
Maintenance Budgeting merupakan hal penting dalam penambangan
batubara. Maintenance Budgeting merupakan proses untuk melakukan
control terhadap budgeting dan planning budget agar kegiatan operasi
produksi dapat berjalan dengan efektif dan efisien. Di dalam modul ini
akan dibahas mengenai hal-hal yang mendukung agar proses
penambangan berjalan secara aman, efektif, efisien, dan sejalan dengan
visi & misi perusahaan. Materi-materi di dalam modul ini bersifat
aplikatif, sehingga mudah dicerna dan diterapkan di lingkungan
pekerjaan.
Modul ini bertujuan untuk meningkatkan kompetensi di bidang
Maintenance Budgeting di tambang tropis, baik secara hard skill maupun
soft skill. Adapun isi modul ini adalah Management Budgeting, Cost
Controlling, dan Plan Cost Structure.
Akhir kata kami berharap semoga Modul Maintenance Budgeting ini
dapat diaplikasikan di lapangan kerja, menambah kompetensi, dan
inspirasi dunia pertambangan.
Yogyakarta, Maret 2020
Tim Penyusun
PT GENTA NUSA ARSANA
– Genta ACADEMY

DAFTAR ISI
Hal
COVER......................................................................................... 1
BIODATA...................................................................................... 2
KATA PENGANTAR........................................................................ 3
DAFTAR ISI................................................................................... 4
BAB I MAINTENANCE BUDGETING………………………………………….… 5

1.1 Process in Maintenance Management System……………………… 7
1.2 Process Grouping to be
OrganizationStructure…………………………………………………………… 7
BAB II. MAINTENANCE PLANNING & BUDGETING………………………. 9

2.1 Definisi………………………………………………………………………………….. 10
2.2 Reference & Literatures ……………………………………………………….. 13
2.3 Cost Grouping – Chart of Account.………………………………………… 14
BAB II. LET’S PRACTICE………………………………….……………………………. 15

3.4 How to Control Cost……….……………………………………………………… 16
3.5 Plant Cost Structure………………………….…………………………………… 17
3.6 Maintenance Costing Flow Process……………………………………….. 17
3.7 Plant Cost Characteristic………………………………………………………… 18
3.8 Why Can be to Over or Tooless………………………………………………. 19
3.9 How to Control?.……………………………………………………………………. 19
LAMPIRAN………………………………….……………………………………………… 21

BAB I
MAINTENANCE
BUDGETING

MAINTENANCE MANAGEMENT

1.1. Processes in MAINTENANCE MANAGEMENT SYSTEM :

• Maintenance Planning & Budgeting
• Maintenance Activities (Process)
• Backlog Management
• Performance Measurement (Technical & KPI)
• Technical Analysis, Development & Support
• Maintenance Improvement & Standardization
• Manpower Management (Planning & Development)
• Tools & Facilities Management
• Equipment Management (Insurance, Warranty Claim, Dispose &
Movement, Maintenance Contract)
• Internal Maintenance Audit System
• Material Supply Management
• Safety, Health & Environment Management
1.2. Process Grouping to be Organization Structure


BAB II
MAINTENANCE
PLANNING & BUDGETING

MAINTENANCE PLANNING & BUDGETING
2.1. Definisi
Sebuah perhitungan untuk membuat Perencanaan dalam Maintenance yang

menggunakan formula tertentu dan membutuhkan data sbb:
• Equipment Population Data (Manufacturer & Model)

• Service Meter Reading (SMR/HM) – Actual & Updated
• Working Hours of Equipment – Planning & Actual
• Maintenance Interval Replacement Time (Every Material for Maintenance :
Service Part, Oil, Grease, & Component)
Output dari perhitungan ini adalah Scheduling (Jadwal Part/Component

Replacement)
Scheduling  Time (Hour, Date, Week, Month & Year) or Quantity Maintenance /
Replacement per Week, Month & Year.

MAINTENANCE PLANNING

MAINTENANCE PLANNING

MAINTENANCE PLANNING to be BUDGETING
2.2. References and Literatures

• Part Book or Part Catalog
• Operation & Maintenance Manual
• Service & Shop Manual
• Equipment Performance Hand Book
• Equipment Sales Mates
• Equipment Data from Manufacturer
• Part & Component Price List
• Standard Man hour for Maintenance
• Microsoft Excel Guidance
• Microsoft Access Guidance
• Others Program Guidance

MAINTENANCE BUDGETING
2.3. Cost Grouping – Chart of Account

• Consumables
• Fuel
• Oil, Grease & Coolant
• Tire
• Undercarriage
• Ground Engaging Tools (GET)
• Drilling Accessories
• Explosives
• Other Consumables
• Repair & Maintenance
• Spare Part (Periodical Service & PCR)
• External Service
• Tools Maintenance (Calibration)
• Maintenance Contract
Cost Grouping is made to facilitate analysis

BAB III
LET’S PRACTICE

MAINTENANCE COST CONTROLLING
3.1. How to Control CO$T?
Steps of Maintenance Cost Control
• Plant Cost Structure
• Business Flow Process
• Plant Cost Characteristics
• Why can be too Over or to Less?
• How to Control?

3.2. Plant Cost Structure
• Consumables
• 422-01  Fuel
• 422-02  Oil & Grease
• 422-03  GET
• 422-04  Tire
• 422-05  Explosives
• 422-06  Drilling Accessories
• 422-07  Undercarriage
• 422-99  Other Consumer
• Repair & Maintenance
• 423-01  Spare Part
• 423-02  External Service Fee
• 423-03  External Service Material
• 423-04  Workshop Tools
• 423-05  General Supplies
• 423-06  FMC
3.3. Maintenance Costing Flow Process

3.4. Plant Cost Characteristics
• Daily Moving
• Fuel
• Oil & Grease
• Other Consumables
• Non Daily Moving
• GET
• Tire
• Drilling Accessories
• Spare Part
• External Service
• Maintenance Contract

3.5. Why can be too Over or too Less?

• PLANT
• Scheduled Maintenance Activity  Not match to Plan
• Unscheduled Repair  Too big
• Wrong Budgeting  Wrong SPO
• LOGISTIC
• Part Check Out Time  Late or not match to Budget
• Part Availability & Lead Time Supply  Bad
• Wrong Account Code  Wrong choose Account Code
(Not Match with Material)
3 . 6 . H o w t o C o n t r o l ?
• PLANT
Wajib & selalu kontinyu memonitor pergerakan Daily Cost dan
melakukan hal-hal sbb:
• Scheduled Maintenance Activity
 Di-prepare setepat mungkin sesuai dengan schedule/budget
• Unscheduled Repair
 Di-minimize agar budget tidak menjadi Over dengan cara
melakukan Maintenance Management System yang
excellent
• Wrong Budgeting
 Selalu mempelajari hasil analisa Cost dan Technical serta
mencari data-data referensi untuk bahan perhitungan
budget yang lebih akurat
• Bekerja sama dengan Logistic dalam memanage Part Check Out
Time dan selalu mengingatkan tentang Part Availability & Lead
Time Supply

• LOGISTIC
• Part Check Out Time
 Ikut memonitor pergerakan cost dan selalu menyesuaikan
dengan budget pada kondisi-kondisi tertentu
 Tidak menunda pekerjaan Check Out untuk Cost dengan
kategori Daily Moving
• Part Availability & Lead Time Supply
 Selalu memperbaiki Part Availability & Lead Time Supply
• Wrong Account Code
 Selalu memasukkan material yang menjadi Cost sesuai
dengan Account Code

LAMPIRAN




PN
MAN MODEL PART NUMBER DESCRIPTION QTY LIFE TIME PRICE USD AMOUNT
REPLACEMENT MAN HOUR
B01 KOMATSU HD465-7 600-211-1231 FULL FLOW FILTER 2 500 11,08 22,17 1,00
B02 KOMATSU HD465-7 600-311-3110 FUEL FILTER 3 500 85,11 255,34 1,50
B03 KOMATSU HD465-7 424-16-11140 TRANSMISSION FILTER 2 500 7,43 14,86 1,00
B04 KOMATSU HD465-7 600-411-1171 CORROSION RESISTOR 1 1000 79,66 79,66 0,50
B05 KOMATSU HD465-7 569-43-83920 BRAKE OIL FILTER 1 1000 92,52 92,52 0,50
B06 KOMATSU HD465-7 07063-51210 REAR BRAKE COOLING 2 1000 135,90 271,80 1,00
B07 KOMATSU HD465-7 600-185-6100 ELEMENT ASS'Y 2 1000 299,88 599,75 1,00
B08 KOMATSU HD465-7 07000-12014 ORING 2 1000 52,16 104,32 1,00
B09 KOMATSU HD465-7 07000-12125 ORING 2 1000 4,07 8,13 1,00
B10 KOMATSU HD465-7 07063-51210 HYDRAULIC FILTER 2 2000 135,90 271,80 1,00
B11 KOMATSU HD465-7 07000-F5180 ORING 2 1000 178,32 356,64 1,00
PRICE PER
MAN MODEL OIL COMPONENT QTY LIFE TIME AMOUNT MANHOURS
LITTER
C01 KOMATSU HD465-7 SAE 30 ENGINE 57 500 1,80 102,60 0,86

C02 KOMATSU HD465-7 SAE 30 BRAKE COOLING 238 2000 1,80 428,40 3,57
C03 KOMATSU HD465-7 SAE 10W FRONT BRAKE 2 6000 1,80 3,60 0,03
C04 KOMATSU HD465-7 SAE 10 STEERING HOIST 122 2000 1,80 219,60 1,83
C05 KOMATSU HD465-7 SAE 30 TRANSMISSION 89 1000 1,80 160,20 1,34
C06 KOMATSU HD465-7 SAE 10W FRONT SUSPENSION 34 12000 1,80 61,20 0,51
C07 KOMATSU HD465-7 NITROGEN FRONT SUSPENSION NITROGEN 82 1000 1,80 147,60 1,23
C08 KOMATSU HD465-7 SAE 10W REAR SUSPENSION 19 12000 1,80 34,20 0,29
C09 KOMATSU HD465-7 NITROGEN REAR SUSPENSION NITROGEN 82 1000 1,80 147,60 1,23
C10 KOMATSU HD465-7 SAE 30 FINAL DRIVE CASE 42 2000 1,80 75,60 0,63
C11 KOMATSU HD465-7 SAE 30 DIFFERENTIAL CASE 95 2000 1,80 171,00 1,43
C12 KOMATSU HD465-7 NLGI-2 GREASE 20 250 2,66 53,20 0,30






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MODUL MAINTENANCE BUDGETING

PT GENTA NUSA ARSANA 1

PT GENTA NUSA ARSANA 2

Yogyakarta, Maret 2020

PT GENTA NUSA ARSANA 3

BAB I MAINTENANCE BUDGETING………………………………………….… 5

BAB II. MAINTENANCE PLANNING & BUDGETING………………………. 9

BAB II. LET’S PRACTICE………………………………….……………………………. 15

PT GENTA NUSA ARSANA 4

PT GENTA NUSA ARSANA 5

PT GENTA NUSA ARSANA 6

1.1. Processes in MAINTENANCE MANAGEMENT SYSTEM :

1.2. Process Grouping to be Organization Structure

PT GENTA NUSA ARSANA 7

PT GENTA NUSA ARSANA 8

PT GENTA NUSA ARSANA 9

MAINTENANCE PLANNING & BUDGETING

Sebuah perhitungan untuk membuat Perencanaan dalam Maintenance yang

• Equipment Population Data (Manufacturer & Model)

Output dari perhitungan ini adalah Scheduling (Jadwal Part/Component

PT GENTA NUSA ARSANA 10

PT GENTA NUSA ARSANA 11

PT GENTA NUSA ARSANA 12

MAINTENANCE PLANNING to be BUDGETING

2.2. References and Literatures

PT GENTA NUSA ARSANA 13

2.3. Cost Grouping – Chart of Account

Cost Grouping is made to facilitate analysis

PT GENTA NUSA ARSANA 14

PT GENTA NUSA ARSANA 15

MAINTENANCE COST CONTROLLING

3.1. How to Control CO$T?

Steps of Maintenance Cost Control

• Plant Cost Structure

• Business Flow Process

• Plant Cost Characteristics

• Why can be too Over or to Less?

PT GENTA NUSA ARSANA 16

MAINTENANCE COST CONTROLLING

3.2. Plant Cost Structure

PT GENTA NUSA ARSANA 17

MAINTENANCE COST CONTROLLING

3.4. Plant Cost Characteristics

PT GENTA NUSA ARSANA 18

MAINTENANCE COST CONTROLLING

3.5. Why can be too Over or too Less?

PT GENTA NUSA ARSANA 19

MAINTENANCE COST CONTROLLING

PT GENTA NUSA ARSANA 20

PT GENTA NUSA ARSANA 21

PT GENTA NUSA ARSANA 22

PT GENTA NUSA ARSANA 23

PT GENTA NUSA ARSANA 24

C01 KOMATSU HD465-7 SAE 30 ENGINE 57 500 1,80 102,60 0,86

PT GENTA NUSA ARSANA 25

PT GENTA NUSA ARSANA 26

PT GENTA NUSA ARSANA 27

PT GENTA NUSA ARSANA 28

PT GENTA NUSA ARSANA 29

PT GENTA NUSA ARSANA 30

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