PQM Consultants | TPM Implementation Plant 2 – SEMEN GRESIK
 

TPM Implementation Plant 2 – SEMEN GRESIK

Objective

In 2010, Semen Gresik (currently known as Semen Indonesia) has a total capacity of the largest cement production, i.e. 19.0 million tons or about 37% of national cement production capacity. The Company is now completing construction of a new cement plant (Plant 4) with an installed capacity of 5 million tons per year.

Their objectives are to optimize current production capacity and to build sustainable growing brand image so it is able to maintain its position as a market leader with a market share of above 45%.

Challenge

Starting on May 2011, to improve the reliability of Plant up-to 30% since the characteristics of the plant is categorized as process industry and typical of maintenance activity is opportunity based maintenance.

Solution

PQM facilitates the Plant 2 as Pilot model, to implement the Total Productive Maintenance (TPM) fundamental pillars, such as 5S and Safety, Focused Improvement (FI), Autonomous Maintenance (AM), Planned Maintenance (PM). By using this TPM approaches, the example result which taken from Raw Mill (Roller Mill) Section can improve the OEE (Overall Equipment Effectiveness) from average 60.2%/month to 85.3%/month (an increase of 25.1%), increase the production capacity up to 36.9% through average running hours of 438 hours/month to 585.7 hours/month. TPM improvement activities also lead their MTBF (Mean Time Between Failures) increase for 134% and MTTR (Mean Time To Repair) down to 12%.