QCC Young on Top For

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ICQCC 2015 Changwon, Korea

ICQCC 2015 - Changwon, Korea Presentation title (Theme)

“ Improving the Performance of Plant 11 – Citeureup

Factory ” Sub-title (Initial Goals)

“ Increasing The Productivity of Finish Mill Process at

the Citeureup Plant–11A, from the existing capacity 93% (168 ton/hour) to the 110% of optimum capacity (198 ton/hour);

within 6

months improvement

period ” Name of the circle Name of Presenters

Company/organization Country

Paper Title

Q C C YOUNG ON TOP 1.

Ricko Achmadi Putra

2.

Hari Winarsa

PT. Indocement Tunggal Prakarsa,Tbk Indonesia

“Increasing The Productivity of Finish Mill Process at the Citeureup Plant–11A, from the existing capacity 93% (168 ton/hour) to 110 % of the optimum capacity (198 ton/hour); within 6 months improvement period”

Name

Q C C YOUNG ON TOP

Job Title and Organization

Plant 11, PT. Indocement Tunggal Prakarsa Tbk., Citeureup Plant, West Java, Indonesia

Contact e-mail address

[email protected] ; [email protected] ; [email protected] ;

QCC Members

Johanes Januar, Ricko Achmadi, Rommy Septiandi, Hari Hermansyah, Difi Nuary, Aas Sunandar

Paper Category

QC Circle/ Small Group Activities

Key Words

Finish Mill, Production Increase, Optimalization

Cost Saving

US$ $ 29.525.935.29 per-year

Abstract PT. Indocement Citeureup , West Java, Indonesia is the big cement factory in single location, 10 plants, 14,4 million tons capacity, has been ISO 14001 Certificate, which indicated the management commitment in managing impact of cement manufacturing on the environment. The plant 11 is the biggest capacity with its great potential increase were decided to various support aspect. The management decided to increase the production performance using various engineer supports Plant 11 by Optimizing Finish Mill area, And QCC "Young On Top" team initiated the theme “Increase Finish Mill Production Capacity In Cement Production Process Finish Mill 11A”.

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ICQCC 2015 Changwon, Korea By PDCA-approach methodology, consist of : 1. Analyze the recent condition and future potential 2. Stratification the issue 3. Analyze and find root causes 4. Planning and actualization the innovation solution especially for : A. Raw material process B. Attractive main process C. Up-graded the finish mill process After measure and check the result QCC "Young On Top" has succeed to increase production line increase 42 ton/hr ( from168 ton/hour to 210 ton/hr). The innovation activities could be identified from various aspect such us : - Dam Ring Reengineered - Purging time system calculation modified - New Installment of Bag filter membrane - New Upgrade operation skill in finish-mill operator There are 2 type of impact resulted : 1. Finish mill capacity increase to 210 ton per hour 2. Cost saving from this improvement about $ 29.525.935.29 per-year. In order to defend that capacity, we implementation maintenance SOP. For next improvement, we would be take theme about power consumption at finish mill area. To maintain our achievement, we established implemented the SOP. The next step has to be done to evaluate the results and take necessary action plans

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ICQCC 2015 Changwon, Korea Step 1: Determining Theme and Title (Initial Goals) – Period WW III January until II February 2013 1.A. Determining the Theme 1.A.1 Identified the Priority Problem The Management is constantly boost the improvement of QMS implementation, in order to achieve the excellent process and best products, in accordance with customer requirement and satisfaction. This Improvement Project based on the SWOT analysis as follow :

SWOT Analysis PT. Indocement Tunggal Prakarsa, Collected by Januar

According to the SWOT analysis, the Plant-11 Manager decided to execute the S-O Strategy as an improvement project in his authority area, so he decided to build the QCC Young On Top as the project executor.

QCC young on top had discussion to determine project to improve production plant P11. We collect from manager report such as the key performance report yearly : 4


ICQCC 2015 Changwon, Korea Key Performance Indicator Evaluation Result and Absolute Target Score, Collected by Rommy

Target Score : 100 From key performance report and discussion with Mr Siswandi as Manager Plant 11, QCC young on top decide to improve Productivity and efficiency esspecially on Capacity fulfillment rate, because this parameter shown that actual capacity is the lowest performance and it has relation with S-O strategy so this parameter must be improved. This is project one sheet that intended for QCC Young On Top :

Management Instruction with One Sheet Project from manager, Collected by Rommy

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ICQCC 2015 Changwon, Korea 1.A.2. Making Conclusion and Formulating the Theme

a)

From the SWOT Analysis, Plant Manager very concern about the S-O Strategy and would like to make it became an improvement project

b)

On the other hand, the KPM evaluate result showing that performance of productivity and efficiency should be improved

c)

Based on the above matters, the Plant-11 Manager decide to build the improvement team.

Then the theme of this project is : " Improving the Performance of Plant 11 – Citeureup Factory"

1.B. Determining the Title IInitial Goals) 1.B.1 Analyzing the Current Situation Data Sheet : Capacity and Actual of Production Sections, Collected by Ricko

Data Sheet : Capacity and Actual of Production Finish Mill Units, Collected by Ricko

1.B.2 Making Conclusion and Deciding The Target (Initial Goals)



Observed the data of comparison between capacity and actual of production section, we recognized that a biggest lack of capasity was in the Finish Mill production Section



Looked at the comparison between Finish Mill units, we knew that the Finish Mill 11-A has the biggest lack of capacity.

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ICQCC 2015 Changwon, Korea Then the Team agreed to determine the Initial Goals that consist of : a quantitave target of achievement and the estimated time of PDCA Cycle time (step 1-5) as follow : “ Increasing The Productivity of Finish Mill Process at the Citeureup

Plant–11A, 110%

from the existing capacity 93% (168 ton/hour) to the

optimum

capacity

(198

ton/hour);

within

6

months

improvement period ”

Suggestion & Comment Plant Manager : Please do coordination with all parties, and take supervise for instal on filed.

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ICQCC 2015 Changwon, Korea Step 2 : Analyzing The Causes – Periode WW III until IV February 2013 2.A The Identification of Root Causes

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ICQCC 2015 Changwon, Korea 2.B Deermining Hypothesised The Dominant Causes by Using Voting No

Causes

JJ

RS

DN

RA

HH

AS

Total

Rankin g

1

Finish

mill

personnel

rarely

5

6

4

4

3

4

26

10

Employees have not received

6

8

9

6

8

7

44

7

checked fluidized 2

training finish mill operations 3

Drying less than optimal

13

13

12

13

13

13

77

1

4

Liner chamber 1 is worn

9

9

7

9

9

8

51

5

5

Bag filter is not good condition

8

7

8

8

7

9

47

6

6

High Rainfall

2

1

2

2

1

3

11

12

7

there should be an alternative

1

3

1

1

2

1

9

13

laboratory material 8

No flow measurement points

7

4

5

3

5

5

29

9

9

There are blocking in ducting

3

2

3

7

4

2

21

11

4

5

6

5

6

6

32

8

12

11

11

12

12

12

70

2

10

10

10

10

11

11

62

4

11

12

13

11

10

10

67

3

outlet CKP 10

Need ball charge

11

Material bed is thin

12

Incorrect

installation

position

membranes 13

Not optimal Purging time

2.C. Conclusion Based on Nominal Group Technique voting data above and by using the rule of nominal group technique formula ½ N (N>6)  7 root causes. The dominan causes that will be tested at the next step are : 1. Dryer material less than optimal 2. Material bed is too thin 3. Not Optimal Purging time 4. Not Optimal installation for membranes position 5. First chamber is worn now 6. Bad Bag filter performance 7. Employees haven’t received Operation training Step 3 : Examining and Verifying the Dominant Causes – Periode WW I until II March 2013 9


ICQCC 2015 Changwon, Korea 3.A. The Hypothesis test of Dominant Causes By using scatter diagram and the minimum coefficient correlation (ρ = 0.714), QCC are able to prove the actual dominant causes. 3.A.1 To examine the domination of “Dryer material less than optimal” Indicator of XρFactor : Inlet temperature (‘C) = 0.9835 Indicator of Y factor : Delta Pressure (mbar) Description : the Rho value = 0.9835, it’s mean this cause is proven dominant

3.A.2

0.9831 of “Material bed is too To examine ρthe=domination thin” Indicator of X Factor : Material CKP feeding (tph) Indicator of Y factor : Material bed thickness (mm) Description : the Rho value = 0.9831, it’s mean this cause is proven dominant

3.A.3 To examine the domination of “Not Optimal Purging time” Indicator of X Factor : Inlet pressure (bar)

ρ = 0.8967

Indicator of Y factor : Delta Pressure (mbar) Description : the Rho value = 0.8967, it’s mean this cause is proven dominant.

3.A.4

To examine the domination ρ = 0.8549 Installation Position Membrane”

of

“Incorrect

Indicator of X Factor : Broken membrane (pcs) Indicator of Y factor : Delta pressure (mbar) Description : the Rho value = 0.8549, it’s mean this cause is proven dominant

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3.A.5 To examine the domination of “Liner Chamber 1 I worn” Indicator of X Factor : Liner Wearing Out (%)

ρ = 0.9534

Indicator of Y factor : Cement Residu 45 (%) Description : the Rho value = 0.9543, it’s mean this cause is proven dominant

3.A.6 To examine the domination of “Bag Filter Is Not Good Condition” Indicator of X Factor : Broken Bag (%)

ρ = 0.9673

Indicator of Y factor : Dust Emission (mg/m3) Description : the Rho value = 0.9673, it’s mean this cause is proven dominant

3.A.7 To examine the domination of “Employees have not received training finish mill operations” Indicator of X Factor : Frequency Trouble

ρ = 0.9412

Indicator of Y factor : Corrective Troubleshooting Description : the Rho value = 0.9412, it’s mean this Afterisexamined all of dominant causes, we know that all of 7 causes have strong relationship with the cause proven dominant effect. It proved by the value of coefficient correlation ()  0.714, as follow : 3.B. The Conclusion

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ICQCC 2015 Changwon, Korea No

Dominant Causes

p

1 Drying less than optimal

0.9835

2 Material bed is thin

0.9831

3 Not optimal Purging time

0.8967

4 Incorrect installation position membranes

0.8597

5 Liner chamber 1 is worn

0.9534

6 Bag filter is not good condition

0.9673

7 Employees have not received training finish mill

0.9412

operations Step 4: Planning and Implementing The Improvement – Period Mach 2013 and Oct 2013 After examined all5W2H solution from impact and easy to fix, we decide to take rank 1 for the solution, as 4.A. – Innovation Solutions follows : 4.A.1 Solution Selection

No

Solution

1 Utilizing the hot air from ESP cooler 2 Installing horizotal dam ring 3 Adjusting the purging time base on delta preasure bagfilter 4 Install membrane on top position 5 Replace first chamber liner 6 Replace Bagfilter with the new one 7 Conduct Training to the new operator employee 12


ICQCC 2015 Changwon, Korea 4.A.2 Planning of Innovation Solution

Dominant Root Cause

1.

Drying less than optimal

Why

In order to decrease humidity material

What

Utilizing the hot air from ESP cooler

Where

Finish Mill 11A

When

April - July 2013

Who

Johanes Januar

How

1.

Project Study

2.

Project Implementation

3.

Trials

4.

Evaluation 100%, inlet temperature CKP dan tube mill ± 220⁰ C

How Much (Target) Dominant Root Cause

2.

Material bed is thin

Why

In order to keep material longer to grind in table

What

Installing horizotal dam ring

Where

Finish Mill 11A

When

July-13

Who

Hari hermansyah

How

1.

Project Study

2.

Project Implementation

3.

Trial

4.

Evaluation


100%, CKP bed Material in good form (± 20 mm) 3.

Not optimal Purging time

Why

Optimizing purging for bagfilter

What

Adjusting the purging time base on delta preasure bagfilter

Where

Finish Mill 11A

When

August 2013

Who

Ricko A.P.

How

1.

Check pressure purging

2.

Setting purging time

3.

Trials

4.

Evaluation 13


ICQCC 2015 Changwon, Korea How Much (Target) Dominant Root Cause

100%, Delta pressure bag filter in good condition (160 mbar) 4.

Incorrect installation position membranes

Why

Agar membran bag filter memiliki life time yang panjang

What

Install membrane on Top position

Where

Finish Mill 11A

When

September 2013

Who

Aas Sunandar

How

1.

membrane condition check

2.

Melakukan perubahan posisi pemasangan membran

3.

Trials

4.

Evaluasi


100%, Damaged membranes decrease less than 5 in 1 month 5.

Liner chamber 1 is worn

Why

Optimization Grinding material

What

Replace liner first chamber

Where

Finish Mill 11A

When

Oktober 2013

Who

Hari Hermansyah

How

1.

Measuring thick liner

2.

Replace liner for first chamber

3.

Trials

4.

Evaluation


100%, Replaced liner first chamber 6.

Bag filter is not good condition

Why

In order to optimize separate material with air

What

Replace bagfilter with the new one

Where

Finish Mill 11A

When

November 2013

Who

Aas Sunandar

How

1.

Check condition of filter bag

2.

Replace filter bag

3.

Trial

4.

Evaluation 14


ICQCC 2015 Changwon, Korea How Much (Target) Dominant Root Cause

100%, all filter bag replaced 7.

Employees have not received training finish mill operations

Why

Employees can do optimization production process

What

Conduct training to the new employee

Where

Finish Mill 11A

When

Oktober 2013

Who

Rommy S.

How

How Much (Target)

1.

Make employee list that need training

2.

arranging training schedule

3.

Training

4.

Evaluation 100%, All operator has good skill for operating Cement mill

After all of the dominant factors have been planned to be repaired, hopefully that the Finish mill 11 A Production capacity can be increased to 198 ton per hour.

Suggestion & Comment Supervisor : Please do coordination with all parties, and take supervise for install on field.

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ICQCC 2015 Changwon, Korea 4.B. Implementing of Solutions DOMINANT

SOLUTION

SOLUTION

CAUSES

IDEAS

IMPLEMENTATION

Drying less

Utilize the

1. Project study

than optimal

hot gas from

2. Location survey

Cooler

3. Calculation for

Electrostatic precipitator

EXECUTOR & DATE

MONITORING & DECISON

April – July 2013

hot gas utilization 4. Design building for hot gas utilizing

Conclusion:

From

the

5. Install modification

above data shows that the

6. Comisioning all

inlet air temperature and

equipment

CKP mill has increased

7. Evaluation

from 27 ° C to 228 ° C with a target of 225 ° C. The decision was taken this improvement SUCCESSFUL.

Material

Make and

bed is thin

install the horizontal

1. 2.

dam ring

Inspect and analyze

July 2013

problem

Rommy

Design additional modification for CKP table

3. 4. 5. 6.

Make horizontal

Conclusion: From the

dam ring


Install horizontal

bed material in the CKP has

damring in to CKP

increased from 12 mm to 20

Trial for No load

mm with a target of 20 mm.

and load codition

The decision was taken this

Evaluation

improvement SUCCESSFUL

Not optimal set the time Purging

Purging

time

based on

1.

Agustus 2013

bag filter puring

Ricko

2. Make purging

Delta pressure

Check pressure for

maping 3.

Change parameter (preasure, timing

Conclusion: From the

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ICQCC 2015 Changwon, Korea 4. 5.

and location)


Compare with delta

delta pressure decreased

preasure

from 200 mbar to 150

Trial another

mbar with a target of 155

combination (stop

mbar. The decision was

when get less delta

taken this improvement

preasure)

SUCCESSFUL.

6.

Fix it

7.

Evaluation

Incorrect

Mounting

1. Location Inspection

September 2013

installation

position of

2. Design modification

Hari

position

the

3. Install modification

membranes

membrane

to

from above

membranes position

correct

4. Evaluation

Conclusion:

From

the

above data shows that the bag

filter

membrane

damage decreased from 13 pcs to 4 pcs with a target of 5 pcs. The decision was taken

this

improvement

SUCCESSFUL.

Bag filter is Replace not

1.

good with a new

condition

filter bag

2.

Inspect and analyze

Oktober 2013

problem

Hari

Check all bag filter on Cement mill 11A

3.

Replace brocken bag filter with new one

Conclusion:

4.

Trial for No load


5.

Give additive for

defective filter bag has

bag filer to get more

decreased from 90% to

durable bag filter

0% with a target of 0%.

Evaluation

The decision was taken

6.

this

From

the

improvement

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ICQCC 2015 Changwon, Korea SUCCESSFUL.

Liner

Replacing

chamber 1

the liner

is worn

chamber 1

1. 2.

Inspect and analyze

December 2013

problem

Rommy

Check First liner chamber cement mill

3. 4. 5. 6.

Give sign for

Conclusion: From the data

brocken liner

above shows that the wear

Replace the brocken

liner chamber 1 decreased

liner (worn liner)

from 85% to 0% with a

Take final inpection

target of 0%. The decision

before test no load

was taken this improvement

After 2500 Hour

SUCCESSFUL

take inspect again 7.

Employees have

not training to

received

employees

1. Make employee list that need training 2. arranging

October 2013 Ricko

training

schedule

training finish

Conduct

Evaluation

mill

operations

3. Training 4. Evaluation

Conclusion:

From

the

above data shows that the employees who received training

have

increased

from 20% to 100% with a target

of

100%.

The

decision was taken this improvement SUCCESSFUL

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ICQCC 2015 Changwon, Korea Step 5: Evaluate The Result – Period October - November 2013 5.A. Evaluate the Initial Goals Achievement Condition

Period Data

Production Capacity (Ton per Hour)

Before Improvement

Nov 2012 – Dec 2013

168

After Improvement

Jan 2014 – Feb 2014

210

5.B. Evaluate the Theme Achievement

Conclusion : Based on the evaluation which was according to data and the graph, it could be concluded that the result which was achieved by the improvement was appropriate with more than initial goal 210 Ton per hour (116%).

5.C. Evaluate the Effects Positive Impact: 1. Added value for the company on over the use of materials that exist in the community / company 2 .Knowledge and experience for employee to do improvement was increasing 3. Team work between employee was increasing 4. The company gain more reliability for Running hour finish mill 5. Individual skill of QCC member was increasing

Efforts were made : Socialization SOP to employees in all Department in Plan 6/11 and and all Employees are given SOP for the operation of Finish Mill with new improvement

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Negative Impact: 1. The quality of the finish mill must be constantly monitored 2. Keep maintenance to the facilities being made in repairs. Action to minimize negative impact : 1. Carry out sampling and quality control mill finish every hour. 2. Carry out routine maintenance

5.D. Evaluate the QCC Competence The Development of each our member in making efforts to vitalization of workshop in continous improvement activities, can be shown using radar chart as bellow:

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Conclusion : Base on the data sheet and Radar Chart above QCC Performance Value (X : 2,20 ) and WorkPlace Challenge (Y : 2,00), before improvement, in Rinda Window, it is located in Zona C (Work Performance and PCDA activities were at average position)and after improvement of QCC Performance(X : 3,50) and Workplace challenge (Y : 3,10) , it is located on zone B which mean that almost all of the work performance were already good and it is achived by using PDCA activities.

Step 6: Making Re-Standarization – Period January 2014 6.A. Standard of Procedure 6.A.1. Standard Procedure of Production Dept. 6.A.1.1 Procedure of Cement Mill 11A Operation 6.A.1.2 Procedure of Cleaning 6.A.1.3 Procedure of Pre grinding CKP Operation with Hot gas 6.A.1.4 Procedure of Inspection And Maintenance Hot gas 6.A.1.5 Procedure of Cleaning Coating at Suspension Preheater 6.A.1.6 Procedure of Used of Feldspar

6.A.2. Standard Procedure of Maintenance Dept. 6.A.2.1 Procedure of Inspection and Maintenance Cement Mill Main drive 6.A.2.2 Procedure of Inspection and maintenance Cement Pre grinding Mill 6.A.2.2 Procedure of Inspection and maintenance Hot Gas Damper

6.B. Standard of Result After all of the procedures have been done consistently, then production capacity has the optimum value 210 Ton per hour within 6 Month.

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ICQCC 2015 Changwon, Korea 6.C. The Superiority to Apply New Standard 1. Increase Finish Mill Production until optimum production 2.Operational system more stable 3.Employee work condition was not under pressure.

Step 7: Implementing the New Standard and Defining Next Project – Period Feb 2014 – Jul 2015 7.A. Monitoring The New Standard Data Source : Schedule Maintenance Data Period : Jan 2014 – July 2015

Reported by : Januar and Ricko Unit : No of problem

Schedule Maintenance and Inspection for Cement Mill

Schedule Maintenance and Inspection for Finish mill Section

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ICQCC 2015 Changwon, Korea Monitoring Total Feeding Cement Mill P11 A (Actual Now) Data Sheet : Cement Mill 11 A Feeding capacity No

Condition

Period Data

No of Problems

1

Before Improvement

Jan 2014 - Apr 2014

168

2

After Improvement

May 2014 - Aug 2014

210

3

Replication 1st

Sep 2014 - Dec 2014

211

4

Replication 2nd

Jan 2015 - Apr 2015

211

5

Replication 3rd

May 2015 - Jul 2015

210

Conclusion: Based on improvement result monitoring can be seen that total feeding capacity Finish mill 11 A in January 2014 until August 2015 period is consistent for 210 ton per hour. The Consistency of the improvement result meet positive result.

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ICQCC 2015 Changwon, Korea 7.B. Socialization of New Condition in The Workplace QCC has socialize the new condition in the workplacce with new standard to the all of the employee which has relation work with Burning Area, Maintenance and company management. Conduct to Procedure document level III (SOP) such as; SOP for operating finish mill for operator central control room, SOP for patroller to check bagfilter condition.

Socialization and discussion Departement electric in meeting rom on Week I December 2015

Socialization and OJT to All Plant 11 employee in meeting rom on Week 2 December 2015

7C. Defining Next Project 7.C.1. Identified After the last project, Manager decide to QCC young On Top for next project, He decide to make process finish mill to be more efficiency. For the first step he tell us to look at Total KWH for 2013 data and make it more efficiency One Sheet Project

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ICQCC 2015 Changwon, Korea Data Source Data Period

: Online Production Report Reported by : Januar : September – December 2013 Unit : KWH / Ton

Power consumsion of finish mill production, that is accoring the data bellow:

Total Power Consumpt

Spesific Power Consumpt

Total Kwh/Ton

Finish Mill A

457.2

Finish Mill B

455.2

Theme statement Based on the data sheet above, it is known that the power consumption of the finish mill 11A is still quite large and could still dlakukan optimization. For that the next time we will continue before the improvement project, "Lower Power Consumption Finish Mill Plant 11A".

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ICQCC 2015 Changwon, Korea Program schedule & Superior Acknowledge :

One way to reduce energy consumption in mill finish is by lowering power play drive by changing the type of lifting from clarifying liner to classifying liner

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QCC Young on Top For

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