MONTHLY MAINTENANCE DEPARTMENT REPORT

PT CEMINDO GEMILANG

OCTOBER 2016

PONTIANAK CEMENT TERMINAL & PACKING PLANT

Doc No. MR / CG / PNK / 010-2016

Signed

Date

DESA WAJOK HULU KEC. SIANTAN

KABUPATEN MEMPAWAH WEST KALIMANTAN

Maintenance Department

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Monthly Report MR 1

TABLE OF CONTENTS

Table of contents

MR 1

Maintenance comments

MR 2

Monthly maintenance activity report

MR 3

Monthly workshop activity report

MR 4

Monthly overtime report

MR 5

Monthly equipment test report

MR 6

CMMS

MR 7

Maintenance organization structure

MR 8

Maintenance Department

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Monthly Report MR 2

MAINTENANCE COMMENTS
A. Maintenance management factory
The definition of maintenance often stated maintenance as an activity carried out for any equipment to ensure its reliability to perform its functions.
Maintenance to most people is any activity carried out on an asset in order to ensure that the asset continues to perform its intended functions, or
to repair any equipment that has failed, or to keep the equipment running, or to restore to its favorable operating condition. Over the years, many
new strategies has been implemented as a maintenance strategies which is intended to overcome the problems which is related to equipment
breakdown.
Maintenance should be a constantly improving activity, which enhances the quality of service and optimizes operating costs. Condition-based
maintenance and predictive strategies based on cutting-edge technologies are arriving on the market and their continuous cost reduction opens
wide opportunities, helping the operation and maintenance personnel to perform tasks more effectively.

B. Maintenance control
With increasing production in the packing plant and to keep the performance of machine in factory, then the activity of preventive and predictive
maintenance implemented seriously.
Maintenance program activities in October for use lubrication of maintenance equipment :
Shell tellus 68
: 20 Liters (additional hydraulic oil ship unloader because rubber hose broken during operation)
Omala S2 G 220
: 75 liters (oil change in schedule maintenance)
Shell Gadus S2 V100
: 16 Pail (extra grease to screw ship unloader)
Shell gadus S3 V100
: 2 Pail (schedule maintenance)
Work improvement and corrective maintenance for the smooth operation of conducted regularly, among others :
Recondition shaft screw ship unloader on side west position (horizontal screw in section 3 and 4)
Replace hanger bearing of horizontal screw on side west position (2 set in section 1 and 3)
Replace rubber belt type flat on long conveyor at packer area (spec belt 650 X EP315 / 3P X 4,0 X 2,0 X 45870 MM)
Installation of safety platform for checkered cement bag in truck loader
Replace new pneumatic cylinder in dust collector 59B BF1 and 6E1 BF2 (2 set with new brand PARKER)
Installation new compressor reciprocating 15 kw to be used only receiving transport system (to reduce power consumption)
Modification of system changes seat bag in roto packer (that has been modified of seat No 1, 2 and 3 for operational effectiveness)
Modification head / tail pulley and replace rubber belt on bag diverter
Maintenance Department

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Monthly Report MR 2

C. Other
To help repair activities on the equipment, we also do a collaboration at the local workshop, Vendor designated to cooperate by management
Pontianak, among others:
* CV. Prima Teknik Inovasi
* Workshop Achun
Equipment repair work, carried out by outsiders :
Recondition shaft screw ship unloader
Work on turning, lathing and milling machine
Repair and service heavy equipment (as guarantee)
Big improvement work
Rewinding motor electric
And others
Outstanding works and improvement also being accelerated for the safety workers, equipment spare parts, maintenance tools, improvement work of
equipment for smooth production in the packing plant.

Maintenance Department

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Monthly Report MR 3

MONTHLY MAINTENANCE ACTIVITY REPORT

No

DATE

CODE

EQUIP. NAME

DESCRIPTION

CORRECTIVE ACTION

DOWNTIME
(MINUTE)

STATUS

1-10-16

61B SG1

Limit switch
bulk loader

Wire rope run up down with not

smooth

Modification position limit switch for

up down wire rope on loading chute

Operation
not stop

Done

2-10-16

6E1 BF2

Centrifugal
vacuum fan

Trips motor in centrifugal fan

6E1-BF2 and make dust collector
system cant run

Repair and overhaul for balancing

shaft and replace seal bearing. Test
run 17 A, vibration 3 -4 m/s2.

360

Done

3-10-16

691 HE2

Wire rope hoist

Wire rope guide plate broken and

make wire rope pleated

Repair and modification guide plate

and resetting sensor switch

30

Done

6-10-16

6E1 SC1

Gearbox head
screw

Broke the gearbox housing

during operation, due to bumped
vessel wall

Repair by welding cast iron on the

gearbox housing

180

Done

8-10-16

600 CP2

Compressor
reciprocating

Reduce power consumption in

receiving transport system

Installation new compressor

reciprocating 15 kw to system

Operation
not stop

Done

11-10-16

6E2 SC2

Horizontal
screw (west)

Horizontal screw runs with noisy

Replace hanger bearing in section 2

40

Done

12-10-16

800 SK1

CAT Skid steer

loader

Maintenance schedule

Change new oil engine, fuel filter,

air filter and oil filter on CAT skid
steer loader

30

Done

13-10-16

661 BD1

Bag diverter

Rubber belt broken

Modification head / tail pulley and

replace rubber belt on bag diverter

360

Done

16-10-16

661 PM1

Packer
machine

Packer operations not effective

because difficulty when changing
seat bag position on roto packer

Modification seat bag with method

sliding system and lock pin. Finish
modification at seat No 1,2 and 3.

Operation
not stop

Maintenance Department

Done

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Monthly Report MR 3

MONTHLY MAINTENANCE ACTIVITY REPORT

No

DATE

CODE

EQUIP. NAME

DESCRIPTION

11

17-10-16

661 3B1

Bin vibrating
screen

Level switch broken on bin

vibrating screen

12

17 21
Oct 2016

6E2 SC2

Horizontal
screw (west)

13

20-10-16

59B BF1
6E1 BF2

14

22-10-16

15

CORRECTIVE ACTION

DOWNTIME
(MINUTE)

STATUS

Replace new one level switch

Operation
not stop

Done

Anticipation screw shaft damage

during operation

Recondition shaft screw with

doubling pipe and install stiffener in
section 3 and section 4

Operation
not stop

On
progress

Dust collector

Indicated of problems in decrease

of air pressure compressor

Replace new rubber membran

(diaphragm) solenoid valve 1 1/2
(with replace 5 set)

120

Done

6E2 SC2

Horizontal
screw (west)

Horizontal screw runs with noisy

Replace hanger bearing in section 1

and 3

Operation
not stop

Done

25-10-16

661 PM1

Packer
machine

Spout packer No 2 & 5 can't run

Re cleaning spout packer No 2 and

No 5 due to block by hard cement

30

Done

16

27-10-16

500 WB2

Weighing
bridge

Weight bridge brand PERISCA

display monitor problem -3010

Check load cell 6 Pcs, result

resistance 750 Ohm, after that in
calibration still problem, We send
for repair monitor to INDODACIN

Operation
not stop

On
progress

17

29-10-16

691 HE2

Wire rope hoist

Gearbox hoist for conveyor truck

loading No 2 can't run

Gearbox components such as low

sliding gear and reverse idler gear
is damaged

480

On
progress

Total Maintenance Downtime (Minute)

Total Maintenance Downtime (%)

Maintenance Department

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Monthly Report MR 4

MONTHLY WORKSHOP ACTIVITY REPORT

No

DESCRIPTION

BEFORE

AFTER

STATUS

Modification seat bag with method

sliding system and lock pin. Finish
modification at seat No 1,2 and 3.

3 seat finish
modification, 5 seat on
progress

Repair by welding cast iron on the

gearbox housing

Done

Replace new pneumatic cylinder in

dust collector 59B BF1 and 6E1
BF2 (2 set with new brand PARKER)

Done

Maintenance Department

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Monthly Report MR 4

MONTHLY WORKSHOP ACTIVITY REPORT

No

DESCRIPTION

BEFORE

AFTER

STATUS

Modification head / tail pulley and

replace rubber belt on bag diverter

Installation of safety platform for

checkered cement bag in truck loader

On progress

Recondition shaft screw with doubling

pipe and install stiffener in section 3
and section 4

Done

Maintenance Department

Done

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Monthly Report MR 5

MONTHLY OVER TIME REPORT

OVER TIME OF MAINTENANCE WORK

DESCRIPTION OVER TIME

INCIDENT

ACTUAL HOURS
(TOTAL)

OVER TIME
(TOTAL)

ESTIMATED PAYMENT
(IDR)

Jobs

17

38

498

Substitutes of permission

23

Substitutes of leave

Substitutes of sick

Project

Total

498

IDR

The use of overtime this month

Maintenance Department

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Monthly Report MR 6

MONTHLY EQUIPMENT TEST REPORT

click link

Maintenance Department

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Monthly Report MR 7

MONTHLY CMMS REPORT

PERIODE OCTOBER 2016

JOB ORDER
No

SECTION

1
2

PM & CM

1
2

JOB
INSPECTION

TOTAL JOB
ORDER
(EXECUTE)

C-C

O-C

O-O

O-P

JO NOT TO US

TOTAL

CM

PM

SH

Maintenance

34

25

24

17

4 Open

Workshop

25

18

14

6 Open

SECTION

TOTAL JO INSPECTION

Maintenance

33

27

11

14

Workshop

16

14

Maintenance Department

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Monthly Report MR 8

MAINTENANCE ORGANIZATION STRUCTURE

PERIODE OCTOBER 2016

ME TL
Muhaimin
ADM. Operation
Nisa P

Workshop

Sukardi

Maintenance Department

Maintenance

H. Dio
M. Ilham
Reza

Local vendor

CV Prima Teknik Inovasi

Workshop Achung

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