“IMPROVE ALL THE TIME, SAFETY ALL THE WAY”

AIMS for Excellence Event 2011

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Team Profile

Project Leader :

Team Member :

Area HeadM. Nazaruddin

Flavius FariodiFacilitator: Miftahudin

Mech. EngineerKayat

Mech. EngineerIndra Z.

SupervisorSujoko S.

Mech. TechnicianFirmansyah M.

Instrument Tech.Nurul Azmi

Maint. PlannerAlvi H.

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Step 1PLANWhat are the improvements opportunity in your area ?

What is the priority for improvement ? Show the data !

Project Description (Background) :Based on record, expending budget for maintenance side had already too high or inefficient, from year to year our budget requirement for equipment become larger and larger. Therefore the main purpose of this project is to reduce maintenance cost itself. What can we reduce ?

Basically WY equipment consist of three main equipment, which are log handling, chip handling and bark handling. The advantages by choosing bark handling project as follow : Bigger opportunity for improvement with more accurates data, knowledge and proportional scope of area as GT. On the other side, choose others will impact into invalid data because every cost on others handling will charge not only to one woodyard line but on all woodyard lines.

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Step 1PLANWhat is the business impact of the project?

What is your project plan ?

Business Impact:Direct Saving Cost : USD 67,894.48 / yrIncrease Production : Production Rate x Saving Time

: 1280 ton / hr x 53.25 mins : 60 = 1136 ton (by reduce downtime)

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Step 3PLANWhat are major drivers of improvement opportunity ?

Show what they are! Please justify with graph or data!

Analysis on Suspected Dominant Causes

1. OEM Bark Crusher spareparts price too costly

No. Description O.E.M. Lifetime / Quality Replace / Year Cost / Year

1 Insert Rubber Coupling $ 33.39 3-4 months 10 EA 4.4 $ 1,469.162 Gable Wearplate $ 4,819.00 4 months 1 SET 3 $ 14,457.003 Grateliner Narrow $ 1,694.97 4 months 3 EA 3 $ 15,254.734 Grateliner Wide $ 1,741.15 4 months 8 EA 3 $ 41,787.605 Hammer $ 19,409.12 Firstly Max 20-25 days 1 SET 1 $ 19,409.126 Filling Piece $ 1,176.92 4 months 1 EA 3 $ 3,530.767 Turning Wall $ 6,226.00 6-7 months 4 EA 2 $ 49,808.00

$ 145,716.37Total Cost Spare Parts :

Qty /Installed

Every year, this is estimation of our maintenance cost for buying spare-parts if we use original equipment manufacture.

So what if we have knowledge, design and material to produce part that have advantages on cost, lifetime and lead time manufacturing ?

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Step 3PLANWhat are major drivers of improvement opportunity ?

Show what they are! Justify with graph or data

2. Inefficient Function of Equipment

Speed switch have function to indicate rotary motion of equipment where they are attached.

Based on this speed switch, we can indicate : 1. Tag No. roller where Motor failure / V-Belt failure2. Chain Cut-Off from roller C 552

So what if there is no speed switch or even gearbox and motor in C551 & C553 ?

Bark Separation Roller Conveyor

C 551

C 552

C 553

C 554

Speed switch

Motor

Chain

Gearbox

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Step 3PLANWhat are major drivers of improvement opportunity ?

Show what they are! Justify with graph or data

3. When bark roller is worn out, replacement price too high

Price / Replacement : USD 6,988.24

Estimation Lifetime OEM : 4 Yrs

Reff. PR 1000182924

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Step 3PLANWhat are major drivers of improvement opportunity ?

Show what they are! Justify with graph or data

5. Missing Cover chain / V-Belt; Curtain Not Complete

Our equipment easy to be exposed, this causes a bad effect on the equipment itself.

Various things that cause the equipment was exposed : Dust on the platform Curtain not complete Missing cover for chain and V-Belt

Cleaning frequency too seldom, not based on schedule Lifetime curtain approx. 1 monthForgot to reinstall cover after V-Belt replacement

Missing Cover Dust / Sliver / Chip on Platform Curtain not Complete

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Step 3PLANWhat are major drivers of improvement opportunity ?

Show what they are! Justify with graph or data

6. Speed too fast; V-Belt worn out abnormally

Cause of this situation :Actual diameter of pulley motor didn’t meet standard requirement, therefore output speed increase from 129.77 m/min to 147.46 m/min

Effect of this situation : • Plug-up risk increase (overload at chute and rechipper) • V-belt, Bearing & Chain will be worn out faster • Bark separation can‘t be done properly (bumping cond.)

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Step 5DOHow is your implementation of measurable actions

that address the root causes ?

1. Alternative source of vendor with acceptable quality

Some of our OEM comes from METSO with delivery time around 2 months, and of course it follows with high price. The idea here is to find alternative source with shorter delivery time & acceptable quality. The result, there are several equipment that have alternative source.

Estimated Saving Cost : $ 60,176.56 / yr

No. Description MC 1 O.E.M. Lifetime / Quality MC 2

Alternate Vendor / Fabricate

First RunDesign

Lifetime / Quality

Actual Lifetime / Quality

Replace / Year Saving Cost

1 Insert Rubber Coupling 40671 $ 33.39 3-4 months 354949 $ 25.28 13-Sep-10 3-4 months 7 months (20.04.11) 10 EA 4.4 $ 356.842 Gable Wearplate 1-28289 $ 4,819.00 4 months 443953 - 443957 $ 2,650.94 19-Feb-11 4 months > 5 months (15.9.11) 1 SET 3 $ 6,504.183 Grateliner Narrow 34088 $ 1,694.97 4 months 34088 $ 892.40 20-Oct-10 4 months 7.5 months (15.06.11) 3 EA 3 $ 7,223.134 Grateliner Wide 34089 $ 1,741.15 4 months 34089 $ 916.49 20-Oct-10 4 months 7.5 months (15.06.11) 8 EA 3 $ 19,791.84

5 Hammer 34087 $ 19,409.12 1st Use: 20-25 days 34087 $ 6,141.44 3-Mar-11 1st Use:

17 days MHW1st Use: 17 days MHW 1 SET 1 $ 13,267.68

6 Filling Piece 199991 $ 1,176.92 6-7 months 199991 $ 654.01 18-Feb-11 6 months N/A (15.06.11) 1 EA 3 $ 1,568.737 Turning Wall 191012 $ 6,226.00 6-7 months 199992 $ 493.92 25-Jun-10 6-7 months 12 months (15.05.11) 1 EA 2 $ 11,464.16

Qty /Installed

Total Saving Cost Spare Parts : $ 60,176.56

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Step 5DOHow is your implementation of measurable actions

that address the root causes ?

3. Fabricate non-drive roller to central W/S instead of buy OEM

Engineering Drawing 3-323-M-1090

Notif. 10190308MO. 4310157

Roller OEM MC. 163473(USD 6,988.24)

Raw material MC. 19893 (USD 1,571.38)

Saving Cost : USD 6988.24 – (1571.38 / 2)USD 6,202.55 / replacement

(lifetime : 4 yrs)6,202.55 / 4 yrs = USD 1550.64 / yr

Raw Material length : 6000 mmRoller length : 2126 mm* Approximately one raw material can be used for two rollers

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Step 5DOHow is your implementation of measurable actions

that address the root causes ?

4. Revised PM Check Form

Before After

Improvement : • Frequency PM Check improve from weekly into daily • Specific item to be checked from each equipment from 25 common items, into

18 special item

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Step 5DOHow is your implementation of measurable actions

that address the root causes ?

5.1. Propose New Cleaning Schedule

Before After

Before Before After After

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Step 5DOHow is your implementation of measurable actions

that address the root causes ?

BEFOREWoodyard #3-4 have allocated manpower 10 peoples for cleaning purposes. However there is no standardization for cleaning. Sometimes area is clean and another day is not.

AFTER• Propose 2 peoples for bark handling equipments• Cleaning schedule every day• Fill checklist form for standardization

Propose New Form

5.1. Propose New Cleaning Schedule (cont.)

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Step 5DOHow is your implementation of measurable actions

that address the root causes ?

5.2. Reinstall all missing cover & curtain

Reinstall all missing cover & curtain when shutdown opportunity.

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Step 5DOHow is your implementation of measurable actions

that address the root causes ?

5.2. Reinstall all missing cover & curtain (cont.)

Reinstall all missing cover & curtain when shutdown opportunity.

Before

After

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Step 5DOHow is your implementation of measurable actions

that address the root causes ?

5.3. Install warning sign on public board and socialization on safety meeting