REDUCING UNPLANNED DOWNTIME FOR UREA PLANT-5 PT. PUPUK KALIMANTAN TIMUR

• Main Author: Dhyatmiko Arifianto, Rikho
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/36359
• Institution: Institut Teknologi Bandung

Urea Plant-5 is the largest urea plant in Indonesia owned by PT. Pupuk Kalimantan Timur (PKT), Bontang. PKT is responsible for subsidized urea demands at 60% of Indonesia's territory while Urea Plant-5 has a contribution of 33% of the company's total production. Since the beginning of the operation, Urea Plant-5 have many unplanned shutdown in the period of 2016 - 2017. This unplanned downtime exceeded the annual target. The consequence is the company loses a profit margin of $ 161,000 per day. This thesis aims to reduce the unplanned downtime of Urea Plant-5 until it reaches the annual unplanned downtime target by finding the problem root cause, determining the solution, testing for 8 months and evaluating the results. By using the methodology approach of Overall Equipment Efficiency (OEE) framework Availability elements, i.e. Mean Time To Failure, Mean Time To Repair, Mean Time Between Failure, downtime performance from the causes can be measured. Unplanned downtime causes are classified into equipment and operational failure where equipment failure are more dominant. To analyze the problem root cause is done by the methodology theory of constraint, by constructing a cause-effect relationship of all possible causes through Current Reality Tree diagram, Evaporating Cloud and giving an injection due to the conflict and then rearranging to get the desired output through Future Reality Tree. The process of finding the problem root causes involved several parties from the production team through brainstorming, questionnaires, discussions with operators and topics discussed at daily meetings. With this methodology, the root cause is the inability of human resources to implement a production management system consistently. The business solution obtained is how to make the production management system work properly through regular reviews on the implementation of Preventive and Predictive Maintenance (PPM) on Urea Plant-5 equipment both task, schedule, observation in the field and discussion of emerging obstacles. Availability of spare parts is also carried out regular reviews to monitor stock status, procurement processes, evaluate min-max, and discuss existing constraints. Enhancing operator capacity by conducting Work Instruction review, Sharing Knowledge activities, Operator presentations, and hiring retiring employees to fill manpower shortages. Although regular PPM reviews are rather difficult to do consistently, the production team is now more concerned about the importance of implementing PPM for plant performance. The implementation of business solutions can significantly reduce unplanned downtime from actual and target gaps of 0.358 to -0.867 days/month and reduce the loss of profit margin by $ 57,638 per month. Unplanned downtime caused by equipment and operational failure is reduced by increasing the % Availability above the target in 2018. The involvement of top-level management in implementing PPM is needed so becomes more consistent and quality. Further evaluation for external causes are recommended which the unplanned downtime for Ammonia Plant-5 will impact to the operation of Urea Plant-5.