bench marking maintenance technology in production based education system polman bandung gotevot...

Project Overview

BENCH MARKING MAINTENANCE

MECHANIC TECHNOLOGY-

(Training for GOTEVOT-Arab Government, May-2001)

VISION & MISSION

OBJECTIVE

”PBE” PROCESS

COMPETENCY

SUBJECT

IMPLEMENTATION

Duddy Arisandi

(Ka. Program Studi Teknik Pemeliharaan Mesin

Politeknik Manufaktur Bandung)

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PREPARE BY DUDDY ARISANDI, S.T. (JULY'01)

Vision & Mission

VISION TO BECAME THE SPEARHEAD OF EDUCATION

AND IMPLEMENTATION OF MAINTENANCE

BASIC SKILL TECHNOLOGY

MISSION TO DEVELOP HUMAN RESOURCES WHO ARE

ABLE TO MAINTAIN, REPAIR AND BUILT

MACHINE TOOLS, GENERAL MACHINE AND

SUPPORTING EQUIPMENT; AND ABLE TO

ASSIMILATE WITH NEW CONCEPT &

TECHNOLOGY IN MAINTENANCE

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Objective

TO TEACH STUDENT IN MAINTENANCE

BASIC SKILL CONCEPT AND PROCEDURE IN

ORDER TO HAVE APPROPRIATE

COMPETENCY WITH INDUSTRY AND HAVE

PROFESSIONAL SKILL

TO MAINTAIN, REPAIR AND BUILT MACHINE

BASED ON STANDARD ACCEPTANCE TEST

TO LEARN, DEVELOPING AND ARRANGE

IMPLEMENTATION OF NEW CONCEPT IN

MAINTENANCE SUCH AS CONDITION BASED

MONITORING, MAINTENANCE CONTROL

SYSTEM, CNC TECHNOLOGY, ETC

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”PBE” Process

INPUT

MAINTENANCE

MECHANIC

TECHNOLOGY

OUTPUT

•STUDENT

•PRODUCT

•MODULAR TRAINING

•ENGINEERING

•CONSULTATION

•COMPETENCY

•PROFESSIONAL

SKILL

•PRODUCT QUALITY

•CUSTOMER

SATISFACTION

•CURRICULUM

•LECTURE

•TEACHING AID

•MODULE

•MACHINE

•TOOLS &

MEASURING INSTRUMENT

•SUPPORTING DATA

PBE : Production Based

Education

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Competency

HOW TO DETERMINE COMPETENCY

IN MAINTENANCE MECHANIC

TECHNOLOGY ?

COMPETENCY IN MAINTENANCE

MECHANIC TECHNOLOGY

BASED ON INDUSTRY

NEEDED AND DEMAND

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3 2

1

Competency INDUSTRY

NEEDED

PRODUCTION

ORDER

TRAINING

ORDER

ENGINEERING

ORDER

CONSULTATION

ORDER

DATA FROM

APPRENTICES

LEVEL OF STUDENT

COMPETENCY

PERIOD OF TIME

MINIMUM

INDUSTRY NEEDED

1. LOWER THAN INDUSTRY NEEDED

2. AGREE WITH INDUSTRY NEEDED

3. HIGHER THAN INDUSTRY NEEDED

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MECHANICAL DRIVE ALIGNMENT (12 %)

Competency

TRAININGS

ORDER

SEAL MOUNTING & DISMOUNTING (1.2 %)

BEARING MOUNTING & DISMOUNTING (13.2 %)

LUBRICANT & LUBRICATION (10.8 %)

HAND SCRAPING (1.8 %)

MAINTENANCE MANAGEMENT (12 %)

MACHINE TOOLS GEOMETRICAL CHECK (7.8 %)

MECHANICAL COMPONENT REPAIR (9 %)

ARC, GAS & SPECIAL WELDING (21.6 %)

BASED ON

MODULAR TRAINING

DURING 10 YEARS

(UNTIL FEBRUARY 2001) :

•167 PACKET

OF TRAINING

•14 SUBJECT OF

MODULAR TRAINING

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Competency

PRODUCTS

ORDER

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Competency

ENGINEERING

ORDER


Subject in ”PBE” Implementation

MAINTENANCE

MECHANIC

TECHNOLOGY

MECHANICAL DRIVE ALIGNMENT (1 WEEK)

BEARING MOUNTING & DISMOUNTING (1 WEEK)

HAND SCRAPING (1 WEEK)

PUMP & COMPRESSOR INSTALLATION (1 WEEK)

LUBRICATE & LUBRICATION (0.5 WEEK)

MAINTENANCE WORK / OVERHAUL (4 WEEKS)

PREVENTIVE MAINTENANCE / ME & FO (8 WEEKS)

MACHINE ASSEMBLY & DISASSEMBLY (1 WEEK)

MILLING & TURNING (6 WEEKS)

MACHINE MAKING (4 WEEKS)

VIBRATION ANALYSIS (0.5 WEEK)

SPARE PART COMPONENT MAKING (4 WEEKS)

PRODUCTION PLANNING & CONTROL (2 WEEKS)

ALL AROUND PRODUCTION (3 WEEKS)

FABRICATION (3 WEEKS)

ELECTRICAL INSTALLATION (2 WEEKS)

SUBJECT FOR ALL

STUDENT IN ONE

YEAR (42 WEEKS)

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Competency

DATA FROM

APPRENTICES

MAINTENANCE SUBJECT SKILL

APPLICATION (60.9 %)

PREVENTIVE MAINTENANCE

PLANNING SYSTEM (26.1 %)

DESIGN

CONSTRUCTION (7.2 %)

SPARE PART MAKING &

MANAGEMENT (5.8 %)

BASED ON APPRENTICES

DURING 1994 - 1997 :

•67 JOURNAL

OF APPRENTICES

•20 - 50 KIND OF INDUSTRY

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Competency

SUPPORTING

DATA F

AB

RIC

AT

ION

(88

.2%

)

BASED ON

KIND OF ORDER

DURING 1997 - 2000 RE

PA

IR,

OV

ER

HA

UL

&

MA

KIN

G

MA

CH

INE

S

(11

.8 %

)

FA

BR

ICA

TIO

N

(70

%)

RE

PA

IR,

OV

ER

HA

UL

&

MA

KIN

G

MA

CH

INE

S

(30

%)

FA

BR

ICA

TIO

N

(31

.6%

)

RE

PA

IR,

OV

ER

HA

UL

&

MA

KIN

G

MA

CH

INE

S

(68

.4 %

)

FA

BR

ICA

TIO

N

(4.8

%)

RE

PA

IR,

OV

ER

HA

UL

&

MA

KIN

G

MA

CH

INE

S

(95

.2 %

)

1997 1998 1999 2000

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Subject GENERAL SUBJECT

BASIC ENGINEERING SUBJECT

NO SUBJECT

T P T P T P T P T P T P

1 RELLIGION 1 1

2 PANCASILA (STATE OF PHILOSOPHY) 2 2

3 NATIONAL RELIANCE

SUB TOTAL 2 0 2 0 1 0 1 0 0 0 0 0

4TH SEM. 5TH SEM. 6TH SEM.

GENERAL SUBJECT

1ST SEM. 2ND SEM. 3TH SEM.

NO SUBJECT


4 MATHEMATICS 2 2

5 PHYSICS 1 1 1

6 SAFETY MEASURED 1 1

7 BASIC MATERIAL SCIENCE 1 1 1

8 BASIC MANUFACTURING PROCESSES 1 1 1 1

9 TECHNICAL DRAWING 1 1 1 1

10 COMPUTER PROGRAMMING 1 1

11 ENGLISH 1 1

12 BASIC ELECTRICAL CIRCUIT 1 1

13 REPORT WRITING 1 1

14 QUALITY MANAGEMENT 1 1

15 SUPERVISION 1 1

16 PROJECT WORK 2 2

SUB TOTAL 8 3 7 3 2 1 2 0 2 0 5 3

4TH SEM. 5THSEM. 6TH SEM.

BASIC ENGINEERING SUBJECT

1ST SEM. 2ND SEM. 3TH SEM.

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Subject

ENGINEERING

SUBJECT

NO SUBJECT


17 MACHINE ELEMENT 1 1 1 1

18 MATERIAL HANDLING & INSPECTION 1 1 1

19 WELDING AND SHEET METAL 1 1

20 ADVANCED MANUFACTURING PROCESSES 3 3 1 1 1 2

21 INTRODUCTION TO MANUFACTURING SYSTEM 1 1

22 PNEUMATICS AND HYDRAULICS 1 1 1

23 ADVANCED MATERIAL SCIENCE 1 1

24 ENGINEERING MECHANICS 1 1

25 STRENGTH OF MATERIALS 1 1

26 TECHNICAL MATHEMATICS 1 1

27 CAD - CAM - CNC 1 2

28 PRODUCTION PLANNING 1 1 1

29 CTS - NC - CNC 1 1

30 PRODUCTION AND INDUSTRIAL PRACTISE 3 2

31 PRODUCTION WORK 2 3

32 PLC (PROGRAMMABLE LOGIC CONTROLLER) 1 1

33 APPLIED ELECTRICITY 1 1

34 MECHANIC CONSTRUCTION 1 1

35 MAINTENANCE MANAGEMENT 2 1

36 MACHINE MAINTENANCE 1 2 1 2

37 MACHINE REPAIR 1 2 1 2

38 MACHINE BUILDING 1 1

39 SPARE PART MAKING 1 1

SUB TOTAL 2 5 3 5 9 7 9 8 9 8 7 6

TOTAL SCUS 12 8 12 8 12 8 12 8 11 8 12 9

5TH SEM. 6THSEM.

ENGINEERING SUBJECT

1ST SEM. 2ND SEM. 3TH SEM. 4TH SEM.

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Implementation

IMPLEMENTATION OF

MAINTENANCE

SUBJECT

MECHANICAL DRIVE

ALIGNMENT

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Implementation IMPLEMENTATION OF

MAINTENANCE SUBJECT

BEARING MOUNTING &

DISMOUNTING

HAND SCRAPING

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MAINTENANCE

SUBJECT

MACHINE ASSEMBLY &

DISASSEMBLY

(INCLUDING

GEOMETRICAL INSPECTION)

HAND TOOLS

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MAINTENANCE

SUBJECT

PUMP & COMPRESSOR

INSTALLATION

LUBRICANT & LUBRICATION

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MAINTENANCE

SUBJECT

MILLING PRODUCTION

TURNING PRODUCTION

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MAINTENANCE SUBJECT

PREVENTIVE MAINTENANCE

MAINTENANCE & REPAIR /

OVERHAUL

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MAINTENANCE

SUBJECT

MACHINE MAKING

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MAINTENANCE

SUBJECT

FABRICATION

(EXAMPLE: ARC WELDING PROCESS)

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MAINTENANCE

SUBJECT

FABRICATION

(EXAMPLE: SHEET METAL PROCESS)

HEAT TREATMENT

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Implementation

SCHEDULE FOR

MAINTENANCE SUBJECT

(1 YEAR = 42 WEEKS)

FOR 26 STUDENT

COIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

351 PSC MW FR PPC BU BA PR PM FK pms MF PSC HS FR MW BU bpm MF PM pms FK

COIN 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

351 PSC MW FR PPC BU BA PR PM FK pms MF PSC HS FR MW BU bpm MF PM pms FK

PSC BA

MW PR

FR PM

BU FK

PPC PPC

HS pms

bpm EI

5TH SEMESTER

6TH SEMESTER

: SPARE PART MAKING

: MAINTENANCE WORK

: BEARING & ALIGNMENT

: ALL AROUND PRODUCTION

: ELECTRICAL INSTALATION: MACHINE ASSEMBLY & DISASSEMBLY

:PREVENTIVE MAINTENANCE

: FABRICATION

: MAINTENANCE FOUNDRY

: HAND SCRAPING : MACHINE MAKING

: MILLING PRODUCTION

: TURNING PRODUCTION

: PRODUCT. PLANNING & CONT.

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Implementation LOAD INSTRUCTOR

(1 YEAR = 42 WEEKS)

FOR 26 STUDENT

19M G/ 4

( I NCO)

18 M G ( S 1 )

P T

( TK1 )

P EM

( 6 M ED)

P EM

( 6 M ED)

P R

( S TM )

P R

( S TM )

P T

( TK1 )

M G

( I NCO)

M G ( S 1 )

M G ( S 1 )

M G

( I NCO)

M G

( I NCO)

25 26

WEEK CALENDAR PROGRAM

34 35 36 37 38 39 4022 23 24 41 42

P T

( TK1 )

16P T

( TK1 )M G ( S 1 )

15M G

( I NCO)

P T

( TK1 )

P T

( TK1 )

14M G

( I NCO)

P T

( TK1 )

P T

( TK1 )M G ( S 1 )

13M G

( I NCO)

P T

( TK1 )

P T

( TK1 )M G ( S 1 )

P T

( TK1 )M G ( S 1 )

12M G

( I NCO)

P EM

( 6 M EC)

M G

( I NCO)

P EM

( 6 M ED)

M G ( S 1 ) M G ( S 1 )M G

( I NCO)

M G

( I NCO)

P T

( TK1 )

P T

( TK1 )

11P EM

( 6 M EC)

P EM

( 6 M ED)

M G ( S 1 )

M G

( I NCO)

M G

( I NCO)

M G

( I NCO)

M G

( I NCO)

P T

( TK1 )

P T

( TK1 )

10P EM

( 6 M EC)

P T

( TK1 )

P T

( TK1 )

P EM

( 6 M ED)

P T

( TK1 )

P T

( TK1 )

9P EM

( 6 M EC)

P T

( TK1 )

P T

( TK1 )

P EM

( 6 M ED)M G ( S 1 ) M G ( S 1 )

P T

( TK1 )

P T

( TK1 )

8P T

( TK1 )

P S C

( 6 M ED)

P EM

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M EC)

P R

( S TM )

P R

( S TM )

P S C

( 6 M ED)

P EM

( 6 M ED)

7P T

( TK1 )

P R

( S TM )

M G

( I NCO)

P S C

( 6 M ED)

P EM

( 6 M ED)

P EM

( 6 M EC)M G ( S 1 )

P EM

( 6 M EC)

P EM

( 6 M ED)

P R

( S TM )

P R

( S TM )

P S C

( 6 M ED)

P EM

( 6 M ED)

M G

( I NCO)

P EM

( 6 M EC)

P EM

( 6 M ED)

P T

( TK1 )

P T

( TK1 )

M G ( S 1 )

6P T

( TK1 )

P T

( TK1 )

P S C

( 6 M ED)

P T

( TK1 )

P EM

( 6 M ED)

P EM

( 6 M EC)

P S C

( 6 M ED)

P EM

( 6 M ED)

P T

( TK1 )

P T

( TK1 )

5P T

( TK1 )

P T

( TK1 )M G ( S 1 )

P S C

( 6 M ED)

P T

( TK1 )

P EM

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M EC)M G ( S 1 ) M G ( S 1 )

P EM

( 6 M ED)

P T

( TK1 )

P T

( TK1 )

P T

( TK1 )

P S C

( 6 M ED)

P T

( TK1 )

4P S C

( 6 M ED)

P R

( S TM )

P S C

( 6 M EC)

P S C

( 6 M EC)

P S C

( 6 M ED)

P S C

( 6 M EC)

P S C

( 6 M EC)

P S C

( 6 M ED)

M G ( S 1 ) M G ( S 1 )

P R

( S TM )

P R

( S TM )

P S C

( 6 M ED)

P EM

( 6 M ED)

P S C

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M EC)

P EM

( 6 M EC)

P S C

( 6 M EC)M G ( S 1 )

P S C

( 6 M EC)

P S C

( 6 M ED)

P S C

( 6 M EC)

P S C

( 6 M EC)3

P S C

( 6 M ED)

P T

( TK1 )

P S C

( 6 M EC)

P EM

( 6 M ED)

P S C

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M EC)

P S C

( 6 M EC)

P T

( TK1 )M G ( S 1 )

P EM

( 6 M ED)

2P S C

( 6 M ED)

P T

( TK1 )

P S C

( 6 M EC)

P S C

( 6 M EC)

P S C

( 6 M ED)

P S C

( 6 M EC)

P T

( TK1 )

P T

( TK1 )

P S C

( 6 M EC)

P T

( TK1 )

P S C

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M EC)

P T

( TK1 )

P S C

( 6 M EC)

P T

( TK1 )

P EM

( 6 M ED)

P S C

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M ED)

1P S C

( 6 M ED)

P S C

( 6 M EC)

P T

( TK1 )

P S C

( 6 M EC)

P S C

( 6 M EC)

P S C

( 6 M ED)

P S C

( 6 M EC)

P T

( TK1 )

P T

( TK1 )

P S C

( 6 M EC)

P T

( TK1 )

P S C

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M EC)

P T

( TK1 )

P S C

( 6 M EC)

P T

( TK1 )

P EM

( 6 M ED)

P S C

( 6 M ED)

P EM

( 6 M EC)

P EM

( 6 M ED)TOTAL AVE.

15 12 9 22 11 11 11 3 9 3 133 16 5 13

27 28 29 30 31 32 33

7 202 9,62

NUMBER OF STUDENTS

4 5

17

P R

( S TM )

P T

( TK1 )

P S C

( 6 M EC)

P S C

( 6 M EC)

P S C

( 6 M EC)

14 79

FOR EXAMPLE:

A INSTRUCTOR

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Implementation

INSTRUCTOR AT

MAINTENANCE MECHANIC

TECHNOLOGY

DUDDY ARISANDI, S.T.

(HEAD OF MAINTENANCE MECHANIC TECHNOLOGY)

DADI KUSNADI

(INSTRUCTOR)

ADE PURNAMA

(INSTRUCTOR)

ANDI NOVIANDI

(INSTRUCTOR)

MUHAMMAD SADIYO

(INSTRUCTOR)

IYAN PURNAMA

(INSTRUCTOR)

•ARC WELDING

•FABRICATION

(PAINTING)

•MACHINE

MAKING

•HEAT TREATMENT

•FABRICATION

(GAS WELDING &

SHEET METAL)

•MACHINE MAKING

•SPARE PART MAKING

•MACHINE MAKING

•PRODUCTION

•PREVENTIVE

MAINTENANCE

•PUMP INSTALLATION

•INDUSTRIAL

TRAINER

•OVERHAUL

•MACHINE MAKING

•BEARING MOUNTING & DISMOUNTING

•MECHANICAL DRIVE ALIGNMENT

•MACHINE ASSEMBLY & DISASSEMBLY

•TESTING MACHINE TOOLS

•HAND SCRAPING

•MACHINE MAKING

•INDUSTRIAL TRAINER

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Implementation

PRACTICAL EXAMPLE :

MECHANICAL

DRIVE

ALIGNMENT

SUBJECT

STUDENT

INSTRUCTOR

MODULE

TEACHING AID

MEASURING TOOLS

SKILL,

QUALITY

BASED ON

INDUSTRY

COMPETENCY

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Implementation PRACTICAL EXAMPLE :

MECHANICAL DRIVE

ALIGNMENT SUBJECT

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Implementation NEED

SYLLABUS

Bench marking

in Basic

Maintenance

Skills with

America,

Australia, and

Holand (we

prove that we

have excellent)

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Implementation

NEED

TEACHING

MODUL

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Implementation

NEED

TEACHING

MEDIA &

LOBORATORY

SAFETY

STATIC TEST

RUNNING TEST

THEORY FACILITY

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Implementation

NEED

COMPETENCY

BASED

ASSESSMENT

Technical Drawing

Machine elements

Plan of operation

Calculation of deviation

Tolerances needed

Fix the deviation

Safety work

Hand tools

Measuring equipment

Interpretation result

Fix the deviation

Static quality testing

Electrical installation

Running test

Measuring method

Make report

Communication

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Thanks You,

Terima kasih,

Jazakumullah