Workshop Target Awareness

2022.03.27

PT. SIMS JAYA KALTIM

Trusted Partner For Your SAFE and GREEN Mining
 Tujuan

- Memahami Target Department Workshop

- Memahami Bagaimana Cara Pencapaian Target
- Memahami Keterlibatan Individu Untuk Mencapai Target
- Memahami Konsep Maintenance Standart
- Meningkatkan Rasa Keperdulian Untuk Pencapai Target

-1/21-
 Alasan

- Perlunya Peningkatan Pemahaman Dan Perhitungan Target Workshop

- Perlunya Peningkatan Keperdulian Terhadap Target Workshop
- Perlunya Peningkatan Pemahaman Terhadap Konsep Maintenance
Stadart
- Perlunya Peningkatan Membuat Strategi Untuk Pencapaian Target
Workshop

-2/21-
 Competency Standard:

- Akan Dilakukan Formative Assessment (Review Dengan Menanyakan

Langsung Di Akhir Topik
- Akan Dilakukan Summative Assessment ( Post Test Setelah Semua
Topik Disampaikan)
- Nilai Minimal Adalah 80%

-3/21-
 Learning Outcome

Setelah pembelajaran selesai diharapkan peserta training mampu

untuk:
1. Memahami definisi dan cara perhitungan dari PA, MA, MTBF, MTTR
dan Service Accuracy
2. Memahami proses pencapaian target PA, MA, MTBF, MTTR dan
Service Accuracy
3. Memahami Konsep Maintenance Standart

-4/21-
 Definisi
Performance Metric:
• Kumpulan dari beberapa alat ukur kinerja perusahaan
• Digunakan sebagai tolak ukur terhadap target
• Sebagai bahan analisa

Key Performance Indicator:

KPI merupakan bagian dari performance Matric yang dipilih sesuai tujuan bisnis

Target:
Tujuan yang diinginkan

Benchmark:
Standart kinerja yang mengacu terhadap suatu standart kelas dunia/mining standart
atau standart dari Perusahaan yang sudah mempunyai pengalaman

Shutdown/Stoppage:
Peristiwa yang membuat mesin tidak bisa beroperasi baik yang ter-schedule
maupun tidak ter-schedule

-5/21-
 Mengapa Perlu Performance Metric?

• Mempunyai Format standart untuk melakukan analisa

• Untuk menilai, mengukur dan mendokumentasikan kinerja
terhadap target yang ditetapkan.
• Sebagai history performance untuk perbaikan selanjutnya.
• Untuk mengidentifikasi masalah, menganalisa dan melakukan
tindakan perbaikan.
• Menentukan skala prioritas terhadap sumberdaya yang ada
• Untuk memonitor progress perbaikan yang sudah dilakukan

-6/21-
 Performance Metric
Metric Metric Description Target Current Bench
Value mark
Service Accuracy Measures the amount of services commenced +/- 25 hours from the recommended 90% 77.2%
service interval
Mean Time Between The average operating time between machine stoppages... the average frequency of 80 Hrs 59.0 hrs
Shutdowns (MTBS) downtime events, express in hours.
Maintenance Ratio The dimensionless ratio of maintenance and repair man-hours to machine operating 0,4 0,5
hours.
% Scheduled Downtime The percentage of total downtime hours performed in a given period that have been 60% 63.7%
planned and scheduled.
Mean Time to First Average Hours to the First Stoppage after a PM Service. Average (First Stoppage Time 120 Hrs 96,7 Hrs
Stoppage After PM After PM - Time PM was completed) measured in Hours
(MTTFSAPM)
Mean Time To Repair The average downtime for machine stoppages... the average duration of downtime 10 Hrs 8,6 Hrs
(MTTR) events, express in hours.
Physical Availability (%) The proportion of time that a machine is capable of functioning in the intended 86% 86%
operation divided by the time that a machine is capable of functioning in the
intended operation plus all forms of downtime, expressed as a percentage.
Availability Index The ratio of MTBS (average shutdown frequency) to the sum of MTBS and MTTR 86% 87.30%
(average shutdown duration), expressed as a percentage
Asset Utilization The proportion of time that a machine is operating (operating hours) divided by the 70% 55%
total calendar time in the period, express as a percentage.

Haul road management Measure severity & haul rod condition 9 10

Payload Target Payload base on CAT reference ≤ 103.4 98.57

tonne tonnes

-7/21-
 Performance Metric
Metric Metric Description Target Current Bench
Value Mark

Overload Payload between 10 to 20 % of target < 15% 22.66%

Overload. Payload over 20% of Target 0% 11.23%

Underload Payload under 10% < 5% < 75.2 T =
2.73%
Application & Operator Induce Event 45 56.4
Operation event/mon Event/mon
th th
Fuel The fuel consumption (average engine fuel burn rate) for a fleet of equipment, express in < 73.80 67.76 Lt/hr
Consumption volume (gallons or liters) per hour. Lt/hours (medium)

Production Production, machine application & utilization, site condition 43,488,000 41,866,608
tonnes tonnes

Payload An analysis of payload distribution for a fleet of Off Highway Trucks express in terms of D H
Management Caterpillar's 10/10/20 truck overload policy.

-8/21-
 Terminology Hours

• Calender Hour => 1 Hari=24 Jam, 1 Minggu 7 Hari=168 Jam, 1 Bulan 30hari=720
Jam, 1 Tahun 365 hari=8760 Jam.
• Available Hours => Jam Unit Siap Operasi
• Breakdown Hours => Schedule & Unschedule Hours
• Operating Hours => Jam unit operasi

• Stand by Hours => Stand by, delay, cuaca, demo, libur nasional dll

Stand by Hours
Operating Hours

All Down
Available Hours Time Hours

Calendar Hour

-9/21-
 Physical Availability

Operating hrs. + Stand-by hrs.

Physical availability =
Operating hrs. + Stand-by hrs. + All downtime hrs.

Stand by Hours
Operating Hours

All Down
Available Hours Time Hours

Calendar Hour

-10/21-
 Mechanical Availability

Operating hrs. + Stand-by hrs.

Mechanical availability =
Operating hrs. + Stand-by hrs. + Mechanical downtime hrs.

Lost Time Hours

Operating Hours

Available Hours MDT NMDT

Calendar Hour

-11/21-
 MTBS & MTTR
Total Operating hours = 310 hours
Uptime 10 70 40 110 80

Downtime 2 8 4 20 15
Total Downtime = 49 hours

Mean Time Between Shutdown:

Operating hours •Indication of the machine quality and
MTBS (hrs.) = the effectiveness and quality of the
Number of shutdowns maintenance workmanship
62 hrs

Total downtime hrs. Mean Time To Repair :

MTTR (hrs.) = •Indication of the serviceability

9,8 hrs Number of shutdowns in the period of the machine and the
efficiency of the repair process

-12/21-
 Increase MTBS & Decrease MTTR

Increase Mean Time Between Decrease Mean Time to Repair

Shutdowns
• Improved quality
– Use genuine parts
– Use well trained , experienced
technicians
– Proper tools & facilities
• Improved durability
– Use genuine parts
– Contamination control
• Identify and Minimize repair delays
– Parts
– Diagnosis
• Move towards Repair before Failure
– Allows us to effectively Plan and
Schedule repairs

• Improved application
– Reduce the stresses on machine

-13/21-
 Maintenance Management Standard
PCR * X

…
Downtime Reasons Unscheduled
Detection Routines Periodic Services Scheduled Repairs PCR
Repairs
(Major & Minor ) Planned Component
Replacement

Maintenance Management Process

PS manages all of the various maintenance-related downtime

scenarios throughout a machine’s lifecycle:
• Condition Monitoring,
• Preventive Maintenance,
• Scheduled repairs (backlog), and
• Planned Component Replacements (PCR).

-14/21-
 Condition Monitoring

• Tujuan:
• Five Elements on Condition
Untuk mendeteksi masalah dan kegagalan
Monitoring
yang akan segera terjadi untuk memfasilitasi
perbaikan terjadi kerusakan dan – Machine Inspections
meminimalkan biaya terkait perbaikan – Fluid monitoring
– Technology / Electronic Data
• Implikasi: – Site Conditions / Application
Condition Monitoring perlu diintegrasikan Analysis
sepenuhnya kedalam kegiatan – Equipment and Repair History
pemeliharaan, untuk memungkinkan Review
planning & scheduling yang efektif,
mengurangi biaya suku cadang, man power
dan workshop cost

-15/21-
 Machine Inspections

Machine Inspection Field Inspections Support Materials

• Daily Inspection
– By operator • Best Practice Condition Monitoring –
– At the fuel bay Field Inspections
• Pre-PM Inspection
80% of pending visual defects could • TA1 / TA 2 Inspections
be detected and registered during
Field Insp. • Inspection Checklists
• During PM Inspection
(assure execution)
• Post PM Inspection
(assure quality)
• Performance Inspection

-16/21-
 Fluid Monitoring

• Scheduled Oil Sampling

• Filter Inspection

• ISO Particle Count

• Ferrous Debris

• Magnetic Plug Inspection

-17/21-
 Fluid Monitoring
Proper SOS Process
• Obtain good fluid samples
– Proper sampling intervals
– Consistent and sequential samples
– Representative samples
• Fully completed sample label
– Particularly make-up oil quantity and hours on oil
• Submit samples promptly
• Submit samples adequately

The Sample Label

• Common problems
– No Information on Bottle
– No Oil Brand or Viscosity Information
– Wrong Machine or Compartment
– No Hours Reported or Inaccurate Value
– Not Fastening the Label to the Bottle
– Not Saying if you’re Looking for Something
– Oil spillage on the label
• The Report is Only as Good as the Information on the Label.

-18/21-
 Fluid Monitoring
What Can Affect SOS Results What The Interpreter Looks For?
• Changes in • Hours on Oil
– Oil brand & grade
• Hours on Machine or Engine
– Filter type & brand
• Trends of all elements (metals)
• Evidence of Contamination
– Application
• Oil Condition and Type
– Operator
• Product History
– Season
• Owner’s Application and Maintenance
– Fuel quality practices
– Oil change actual period

Fluid Monitoring – Filters & Magnetic Plugs

Fluid Monitoring - Trending SOS Data • SOS Not Effective on Particles > 8 microns
• Trending is the most reliable and accurate • Physical Inspection
method of interpreting the results ‒ Magnetic Plugs
• What is “Normal” for your Operation? ‒ Filters
• When Changes are Found ‒ Including Cutting
‒ Find Why ‒ Screens
‒ Generate Action ‒ Strainers
• Too often the data exists • Exchange Components
‒ … no action is taken ‒ Clean Screens, Mag Plugs etc.
• Look for larger particles, chips, debris …
still the best way to monitor Differentials & Final
Drives
-19/21-
 Backlog Management:

Cacat / kondisi abnormal terdeteksi pada peralatan di mana perbaikan dapat ditunda
sampai waktu yang ditentukan

Respon yang direncanakan untuk masalah yang terdeteksi/Kondisi tidak normal

Manajemen Backlog adalah fungsi logis yang mendukung Rencana Pemantauan

Kondisi alat

Harus:
• Terorganisir
• Ditentukan tingkat urgency
• Termonitor
• Terukur.

-20/21-
 Backlog Management

Backlog Management

Symptom Planning Failure

?
3.- Planning define the plans
and actions to execute the
repairs

1.- Symptom of
Deterioration 5.- Learning from Failures

2.- Detection Routines

(Condition Monitoring) 4.- Repair Execution
(Repair Before Failure)
time

-21/21-
 Process Review
Manage

Plan & Schedule

Generate Execute

Facilities, Parts Labor Others

Equip.

Measure

-22/21-
 Backlog Management Process

Backlog Backlog
Prioritizing Planning
Capture Performed

• P1 Immediate action
• Execute backlog
• P2 Next PM action
on PM or other
• P3 Next opportunity • Resources
maintenance event
• Daily Inspection planning (Part,
• Operator comment labor and tools)
• PM performed • Scheduling
• Condition Monitoring
• PS/PI

-23/21-
 Thank you

-24/21-