ANALYSIS OF SHUTDOWN SCHEDULE AT CRUSHER MASTER PLANT STUDY CASE AT PT FREEPORT INDONESIA

• Main Author: ONTORJO 29115290 , EKO
• Format: Theses
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/21907
• Institution: Institut Teknologi Bandung

Mill Concentrating Division is one of the operation division within PT Freeport Indonesia that have <br /> <br /> crucial role and significant function on processing rocks until the final result (concentrate). To <br /> <br /> produce a concentrate, rocks will through into various processes and equipment. Similar with others <br /> <br /> divisions, the cost of equipment procurement and its maintenance included as major element of <br /> <br /> operations. In concentrating division, there is a plant which calls CRUSHER MASTER PLANT <br /> <br /> (CMP). Within this plant system, there are three train circuits that flowing ore as South Train, North <br /> <br /> Train, and Middle Train. Currently, there will be a shutdown schedule plan that regularly conducted <br /> <br /> as once a week for 12-14 hours due to equipment maintenance program. They will require additional <br /> <br /> manpowers from the external resources (contractors) for every shutdown, the outsource resources will <br /> <br /> be combined with PTFI senior resources (employee) to accomplish several tasks. <br /> <br /> Due to current company situation and corporate policy also, CMP maintenance team still cannot hire <br /> <br /> new employee to fill those vacant positions within their Organization Chart. With only 34 employees <br /> <br /> on maintenance teams, they need to maintain more than 200 equipments at CMP. Therefore, they are <br /> <br /> significantly lack of senior manpower to help them in Mill shutdown project. Maintenance teams of <br /> <br /> CMP have more than 94 of routine task that need to be resolve in each shutdown, if they receive <br /> <br /> additional request task from planner then they need to cancel several of routine task. This sequences <br /> <br /> has repeated and generate contribute increase backlog task of maintenance. With large of tasks that <br /> <br /> not done by maintenance teams, maintenance style in CMP became reactive maintenance (breakdown <br /> <br /> maintenance) which mean several of equipments will be maintain when failure. In the end, it will <br /> <br /> increase unscheduled shutdown (downtime). Thus, CMP need to develop the appropriate shutdown <br /> <br /> schedule to increase availability and tonnage. <br /> <br /> Based on further focus group discussion (FGD) internally with Operation, Maintenance, and Planning <br /> <br /> department at CMP, several scenario have been raised up such as; change schedule of shutdown, <br /> <br /> change of work schedule for employees and having sub-contractor to do those several tasks within the <br /> <br /> CMP. The scenario were analyzed by SMART method to get the optimum result. Lifetime liner, <br /> <br /> contractor cost, labor cost, and materials cost will became consideration to decide the scenario. On <br /> <br /> the achievement attribute like safety, revenue, labor retention, and fatigue management will became <br /> <br /> benefit that need to be achieved. <br /> <br /> The best scenario (scenario 6) taken is to keep existing work schedule that is five days’ work and two <br /> <br /> days off (5-2) and combine by switch two type shutdown tasks namely replacement rollers at belt <br /> <br /> conveyor and panels deck at Primary Wet Screen, Secondary Wet Screen and tertiary Dry Screen to <br /> <br /> be outsources by contractors, and changing shutdown schedule became once per two weeks. This <br /> <br /> scenario is an efficient option with the highest compliance based on SMART analysis. <br /> <br /> i <br /> <br /> With this scenario, although contractor cost increase 48% but for other attribute benefit increase as <br /> <br /> follow: safety performance increase 60%, labor retention increase 40%, fatigue management increase <br /> <br /> 60%, and the last revenue increase 4%. <br />