Pom - Workshop Management 20131023

WORKSHOP MANAGEMENT IN PALM OIL MILL
SELAYANG PANDANG dwisoeprapto@instiper.ac.id 23 October 2013

Workshop Management dwisoeprapto@instiper.ac.id 1
POM - WORKSHOP MANAGEMENT
Workshop Management
dwisoeprapto@instiper.ac.id

PALM OIL MILL INDUSTRY
OIL PALM ESTATE

SDM ALAT MESIN WASTE
PALM OIL MILL
PALM OIL REFINERY & DOWNSTREAM INDUSTRY

Workshop Management dwisoeprapto@instiper.ac.id
MIDDLE & FINAL PRODUCT

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SDM - Mekanik
SDM - Operator
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POM - MACHINERY TECHNOLOGY

Alat Mesin Proses Palm Oil Mill SDM - Operator
Stasiun Pendukung :
Pembelian Suku Cadang Alat Mesin

Alat Mesin Perbengkelan Energi Listrik Bahan Pelumas Alat Mesin
Perawatan Alat Mesin - Routine

Pengujian Alat Mesin Reparasi Kerusakan Alat Mesin Pengadaan Suku Cadang Alat Mesin Nama Alat Mesin : Fungsi : Prinsip Kerja :
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SKEMATIKA
Langkah Proses :
Machinery Technology
dwisoeprapto@instiperjogja.ac.id

MANAGEMENT Tatakelola atau ilmu / tatacara dalam mengurusi suatu kegiatan WORKSHOP Bengkel / bagian mengurusi kegiatan yang berkaitan dengan keteknikan / alat mesin
POM Palm Oil Mill / Pabrik Kelapa Sawit


LINGKUP BAHASAN Pabrik Kelapa Sawit Palm Oil Mill Alat Mesin di PKS / POM Struktur Organisasi di PKS / POM Lingkup Kerja Asisten Mill Lingkup Kerja Asisten Workshop Metoda Pemeliharaan Alat Mesin
Planned Preventive Maintenance Breakdown Repair Penyediaan suku cadang alat mesin
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A. STRUKTUR ORGANISASI PABRIK KELAPA SAWIT
PALM OIL MILL HEAD ASSISTEN DISPATCH & EQUIPMENT
MILL HEAD
ASSISTEN PRODUKSI SHIFT A ASKEP PRODUKSI ASSISTEN PRODUKSI SHIFT B ASSISTEN MAINTENANCE ASKEP MAINTENANCE ASSISTEN ELECTRIC
ASSISTEN PERSONALIA/GA
ASSISTEN QHSE PKS ADMIN ASSISTEN PROJECT PKS ADMIN
ASSISTEN LABORATORIUM
ASSISTEN LOGISTIK
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Lingkup Kerja Asisten Mill
Mengelola sumberdaya Manusia dan Alat mesin untuk tujuan produksi yang tingkat produktivitasnya sesuai.
Lingkup Kerja Asisten Workshop Mengelola sumberdaya Manusia dan Alat mesin untuk tujuan mengawal / menjaga kehandalan alat mesin produksi.

Tabel Jadwal Pemeliharaan Alat Mesin
Periode Tahunan Periode Bulanan
Tindakan Perbaikan Darurat Alat Mesin Pengelolaan Suku Cadang Alat Mesin
Pengadaan Pembelian Suku Cadang Alsin Pengadaan Pembuatan Suku Cadang Alsin Penyimpanan Suku Cadang Alat mesin

Predictive Maintenance Tindakan Mendiagnosa kerewelan Alsin Tindakan Menganalisa Hasil Diagnosa Tindakan Perbaikan Yang diperlukan Tindakan Pembongkaran Alat Mesin, perbaikan & penggantian suku bagiannya Tindakan Pemasangan kembali Alat Mesin dan suku bagiannya
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What is Total Productive Maintenance?

TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results
Breakdown of TPM
TOTAL = All encompassing by maintenance and production individuals working together PRODUCTIVE = Production goods and services that meet or exceed customers expectations MAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all times
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Troubleshooting
Adalah suatu cara pendekatan sistematik untuk menebak atau melokalisisir terjadinya kegagalan fungsi suatu alat mesin atau system.
Troubleshooting
Adalah suatu keahlian yang terlatih, tidak semua proses troubleshooting sama persis.
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Troubleshooting
Para teknisi cenderung untuk meningkatkan atas keahlian Troubleshooting mereka itu berdasarkan pengetahuan dan pengalaman pribadinya.
Preventive maintenance
Program Preventive maintenance yang baik akan bermanfaat dalam mendukung pengecilan ataupun pengurangan kegagalan fungsi pada suatu alat mesin.
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Management in all business and organizational activities is the act of getting people together to accomplish desired goals and objectives using available resources efficiently and effectively. Management comprises planning, organizing, staffing, leading or directing, and controlling an organization (a group of one or more people or entities) or effort for the purpose of accomplishing a goal. Resourcing encompasses the deployment and manipulation of human resources, financial resources, technological resources, and natural resources.

Management
Management in all business and organizational activities is the act of getting people together to accomplish desired goals and objectives using available resources efficiently and effectively..
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Management
Management comprises planning, organizing, staffing, leading or directing, and controlling an organization (a group of one or more people or entities) or effort for the purpose of accomplishing a goal.
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Management
Resourcing encompasses the deployment and manipulation of human resources, financial resources, technological resources, and natural resources.
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Basic Functions
Management operates through various functions, often classified as planning, organizing, staffing, leading/directing, and controlling/monitoring.i.e Planning: Deciding what needs to happen in the future (today, next week, next month, next year, over the next 5 years, etc.) and generating plans for action. Organizing: (Implementation) making optimum use of the resources required to enable the successful carrying out of plans. Staffing: Job Analyzing, recruitment, and hiring individuals for appropriate jobs. Leading/Directing: Determining what needs to be done in a situation and getting people to do it. Controlling/Monitoring: Checking progress against plans. Motivation : Motivation is also a kind of basic function of management, because without motivation, employees cannot work effectively. If motivation doesn't take place in an organization, then employees may not contribute to the other functions (which are usually set by top level management)
Basic Functions
Management operates through various functions, often classified as planning, organizing, staffing, leading/directing, and controlling/monitoring.i.e
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Planning: Deciding what needs to happen in the future (today, next week, next month, next year, over the next 5 years, etc.) and generating plans for action. Organizing: (Implementation) making optimum use of the resources required to enable the successful carrying out of plans.

Staffing: Job Analyzing, recruitment, and hiring individuals for appropriate jobs. Leading/Directing: Determining what needs to be done in a situation and getting people to do it.
Controlling/Monitoring: Checking progress against plans.


Motivation : Motivation is also a kind of basic function of management, because without motivation, employees cannot work effectively. If motivation doesn't take place in an organization, then employees may not contribute to the other functions (which are usually set by top level management)
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Tabel Jadwal Pemeliharaan Alat Mesin Tahun ...........
Palm Oil Mill :........................................................ Lokasi: .........................
No Nama Alat Mesin & Kapasitas

1. 2. Weightbridge Weightbridge
No. Mesin
WB 01 WB 02
Bulan ke
1 2 3 4 5 6 7 8 9 10 11 12
I I
I I
3.
4. 5. 6.
Loading Ram
Loading Ram Transfer Carriage Transfer Carriage
LR 01
LR 02 TC 01 TC 02
I
I I I
I
M I
I
I I I
S
I
I I
I
S
7.
8.
Sterilizing Unit
Sterilizing Unit
ST 01
ST 02
I
S
I
I
S
I
I
I
S
I
I
S
I
I
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M
I
I : Inspection
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S : Small Repair
M : Medium Repair
O : Overhaul

Tabel Jadwal Pemeliharaan Alat Mesin Tahun ........Lanjutan No Nama Alat Mesin & Kapasitas 9. 10. 11. 12. 13. 14. 15. 16. 17. Tipper Unit Tipper Unit Threshing Unit Threshing Unit Scrap Conveyor Screw Conveyor Bucket Elevator Digester - Press Digester - Press No. Mesin TP 01 TP 02 TH 01 TH 02 SC 01 SCE 01 BE 01 DP 01 DP 02 I I M S S
M
Bulan ke
1 2 3 4 5 6 7 8 9 10 11 12
I I I I
S I
I I I S
I M I
S S I I
M I S
I I S I
I
I I
S M
I I
M I S I
S M
I I
M I S I
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S M
I : Inspection
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S : Small Repair
M : Medium Repair
O : Overhaul

Contoh
Simulasi Tabel Jadwal Pemeliharaan Alat Mesin POM / PKS Simulasi Tabel Jadwal Pemeliharaan Alat Mesin / Planned Preventive Maintenance disusun berdasarkan prediksi awal atas kinerja operasi Alat Mesin yang bersangkutan. Bilamana Alat Mesin tersebut beroperasi lebih berat dari prediksi awal, maka tenggang waktu jadwal pemeliharaan / service sebaiknya diperpendek / lebih sering di-service . Apabila Alat Mesin tersebut beroperasi lebih ringan dari prediksi awal, maka tenggang waktu jadwal pemeliharaan / service dapat diperpanjang / lebih jarang di-service. Tindakan tersebut di atas diambil dengan pertimbangan yang mendalam berdasar pengalaman & kenyataan yang ada.

Contoh - Lanjutan
Simulasi Tabel Jadwal Pemeliharaan Alat Mesin POM / PKS Pertimbangan lainnya adalah bagaimana membagi beban kerja secara seimbang sepanjang tahun kerja pelayananan, dan pada waktu panen puncak diharapkan Alat Mesin dapat beroperasi secara layak menurut SOP yang ada. Pada saat beban operasi POM / PKS memuncak, maka hindarilah pemeliharaan / service berat / membongkar Alat Mesin, sebaiknya digeser waktunya pada saat keadaan telah memungkinkan kita melakukan tindakan tersebut, akan tetapi service ringan / reparasi pemogokan (Breakdown Repair) tetap dilaksanakan sebagaimana mestinya.
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Kartu Laporan Kerusakan Alat Mesin
Pada hari ini :........................ Tanggal :.......................... Pukul :........... dilaporkan telah terjadi kerusakan / pemogokan Alat Mesin, pada : Suku Bagian Alat Mesin :................................................................... Nama Alat Mesin : ...........................................................No.: ................ Stasiun Proses :.............................................................. Line : ......... Mohon perhatian dan bantuan perbaikannya dengan segera. Terimakasih atas kerjasamanya. Berdasarkan laporan kerusakan / pemogokan Alat Mesin, telah dilakukan pada tindakan pemeriksaan dan perbaikan segera pada Alat Mesin yang dimaksud, dengan memerlukan suku cadang : Nama Suku cadang Alat Mesin :........................................................... Spesifikasi : ..................................................... sejumlah: ................... Tanggal : ........................ Mengetahui :........................... Pengawas :.................... Mekanik :................
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Bon Pengambilan Suku Cadang Alat Mesin
Pengambilan Suku Cadang untuk : Nama Alat Mesin : ...........................................................No.: ................ Stasiun Proses :.............................................................. Line : ......... No. Nama Alat / Suku Cadang Jumlah Keterangan
Tanggal : ........................ Mengetahui :.......................... Penerima :.................... Penyerah :..................

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Kartu Stok Suku Cadang Alat Mesin
Nama Suku Cadang : ..................................... No. Kode : ..................... Spesifikasi khusus : ................................................................................ Nama Alat Mesin : .............................................. Bagian : ..................... Stasiun Proses :...................................................... Line : ......... No Tanggal Keterangan untuk Masuk Keluar Sisa Paraf
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Kartu Riwayat Alat Mesin
Stasiun Proses :............................................................. Line : ......... Nama Mesin : ..................................................................No.: ........... Elektro Motor : .........................................; Daya : .........kW / Phasa :........ .........................................; Daya : .........kW / Phasa :........ Boks Pelumas :................; Jenis Pelumas :.............; Jumlah :........CC ................; Jenis Pelumas :.............; Jumlah :........CC ................; Jenis Pelumas :.............; Jumlah :........CC No Tanggal Keterangan Pemeliharaan Alat Mesin Teknisi Mengetahui
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Kartu Riwayat Alat Mesin (Lanjutan)
Stasiun Proses :............................................................. Line : ......... Nama Mesin : ..................................................................No.: ........... No Tanggal Keterangan Pemeliharaan Alat Mesin Teknisi Mengetahui
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WORKSHOP MANAGEMENT IN PALM OIL MILL

SELAYANG PANDANG dwisoeprapto@instiper.ac.id 23 October 2013

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

OIL PALM ESTATE

PALM OIL MILL

PALM OIL REFINERY & DOWNSTREAM INDUSTRY

MIDDLE & FINAL PRODUCT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - MACHINERY TECHNOLOGY

Pembelian Suku Cadang Alat Mesin

Perawatan Alat Mesin - Routine

POM - WORKSHOP MANAGEMENT

POM Palm Oil Mill / Pabrik Kelapa Sawit

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

ASSISTEN QHSE PKS ADMIN ASSISTEN PROJECT PKS ADMIN

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

What is Total Productive Maintenance?

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

Controlling/Monitoring: Checking progress against plans.

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

POM - WORKSHOP MANAGEMENT

No Nama Alat Mesin & Kapasitas