Alumina Processing Process ICA Production 2015

Presented by :

Abigail Anang Pratama

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Abigail Anang Pratama

Education :

S1 Chemical Engineering

Universitas Negeri Sultan Ageng Tirtayasa – Banten

Work experience:

SPV Alumina Processing Process - PT. ICA

Tayan - Kalbar (Oct. 2013 – Now)

Officer Process Sulphonation & Detergent – PT. Sinar Antjol

Tangerang - Banten (Dec 2012 – Sept 2013)

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Overview

Structure Organization AL-2 Production

Introduction to Process APRP

Report Achievement Quantity Target & Quality of Alumina Processing Process - ICA Production Period January – October 2015

On going Improvement

Next plan Improvement 2016ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Structure Organization AL-2 Production

AL 2 Production Manager

Sidik Gandana

SI APRP (Temporary)

Rinto dh

SPV AG1 & AG2

Abigail Anang

SPV AB123 & ARE

Satriawan

SPV AG3 ATR & AAN

Noven Enggar S

SI HPRP

(Temporary)

Rinto dh

SI Calcination

Muammar

Foreman Day

Rendi

Foreman Shift (ABCD)

Eka, Heri, Rahmad, Ya dwi

28 Operators 23 Outsourcing

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Introduction to Process APRPProses Main Equipment Total Brand Name

ProductExample Brand Name

Alumina Grinding 1 (AG1) Tube mill (continue operation)

10 Products A-42-2 , A-42-6 , etc.

Alumina Grinding 2 (AG2) Jet mill ( continue operation)

1 Product A-44J

Alumina Grinding 3 (AG3) Ball mill (batch Operation) 25 Products A-43-L, AL-160SG-3 , etc.

Alumina Blending (AB) 1 2 3 Tank Blending (batch Operation)

38 Products A-12-40M, A-13-M-BL , etc.

Alumina Repacking (ARE) Tank (batch Operation) Only repacking Repack product to (C75) or (C87) , etc.

Alumina Surface Treatment (ATR)

Mixer (batch Operation) 3 Products A-42-2ST-H, AL-43MS-T

Alumina Annealing (AAN) Electric Furnace(batch Operation)

1 Product AL-160SG-4ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Report Alumina Processing ProcessICA Production 2015

Achievement Quantity Target of Alumina Processing Process

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

PEN

CA

PA

IAN

% Quantity Main Product Target from PPD

-

500

1,000

1,500

2,000

2,500

3,000

Jan Feb Mar Apr May Jun Jul Aug Sep Oct

Ton

Tahun 2015

Alumina Processing Process - ICA Production 2015

Total Production Target in APrP Total Packaged in APrP

PeriodeTarget Produksi

from PPD (Kg)Total Produksi (Kg)

Total Produksi

yang sesuai

Target PPD (Kg)

Persentase

pencapaian

target PPD

Januari - 495,650 - #DIV/0!

Februari 277,825 948,176 108,200 38.9%

Maret 643,410 1,979,949 15,948 2.5%

April 736,900 774,823 173,117 23.5%

Mei 1,433,540 921,440 339,202 23.7%

Juni 1,623,000 2,262,625 950,000 58.5%

Juli 2,050,875 1,503,720 986,389 48.1%

Agustus 1,995,750 682,224 380,700 19.1%

September 1,210,575 479,348 348,000 28.7%

Oktober 2,409,050 2,082,569 1,166,575 48.4%

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Report Alumina Processing ProcessICA Production 2015

Achievement Quality of Alumina Processing process

Data Quality Alumina Processing process

Produk Selesai Analisa Produk On-Spect Produk Reject

Target 80% Maximal 20%

Januari 26% 45.3% 54.7%

Februari 43% 86.8% 13.2%

Maret 50% 100.0% 0.0%

April 60% 100.0% 0.0%

Mei 37% 100.0% 0.0%

Juni 68% 100.0% 0.0%

Juli 30% 100.0% 0.0%

Agustus 15% 96.6% 3.4%

September 14% 100.0% 0.0%

Oktober 1% 90.9% 9.1%

Percentage Data quality Product Alumina Processing

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Target Januari Februari Maret April Mei Juni Juli Agustus September Oktober

% On-Spect Quality Produk Alumina (APrP)

Process

Total Produksi

(Kg)

Produk Selesai analisa

(Kg)

Reject Produk

(Kg) On-Spect (Kg)

Januari 495,650 127,875 70,000 57,875

Februari 948,176 408,774 54,000 354,774

Maret 1,979,949 990,181 - 990,181

April 774,823 465,251 - 465,251

Mei 921,440 345,000 - 345,000

Juni 2,262,387 1,527,855 - 1,527,855

Juli 1,503,720 446,895 - 446,895

Agustus 682,224 101,325 3,450 97,875

September 479,348 69,000 - 69,000

Oktober 2,082,569 22,000 2,000 20,000

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

On Going Improvement

Improvement

Man

Awareness Safety

Awareness Neatness

Method Manage Area

Machine

MoneyModificationABIG

AIL A

NANG PRATAM

A

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Improvement & Corrective Action (1)

The hygiene at Work Area

Issue :

Work area dirty condition

Mixed messy condition between waste alumina powder, plastic and jumbo bag after charging

Lack of awareness of workers against The hygiene at Work Area

Problem solving :

Make standard regulation the hygiene at Work Area

Training to operator & outsourcing

Controlling with foreman & SPV

Benefit :

The hygiene at work area preserved

Arises a sense of comfort and sense of belonging,

And increasing the sense of responsibility for each work area

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

The hygiene at Work Area

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

The hygiene at Work Area

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Improvement & Corrective Action (2)

Neatness Packing Paper Bag

Issue :

Forming Paper bag not stable & not neat

Paper bag dirty (by powder)

Complain / claim from costumer

Cancel sales from costumer

Problem solving :

Make standard regulation forming Paper bag

Training to operator & outsourcing

Controlling with foreman & SPV

Cooperate with Team PPD & PKSS

Benefit :

Forming Paper bag good & neat

Avoid broken product / claim costumer

Reach Costumer satisfaction

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Neatness Packing Paper Bag

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Improvement & Corrective Action (3)

Mapping Area Raw Material (Genrio)

Issue :

Work Area untidy

Untidy raw material AL5-1/2/3

Very difficult search raw material, if Work Area untidy

Delay Transfer raw material from warehouse

LOSS TIME = Decrease Production base

Problem solving :

Make standard regulation / Mapping area for raw material (Genrio)

Training to operator & outsourcing

Controlling with foreman & SPV

Cooperate with Team PPD & PKSS

Benefit :

Raw material organized tidy

Easy find Raw material

Reduce LOSS TIME

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Mapping Area Raw Material (Genrio)

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Improvement & Corrective Action (4)

Increase Base AG1 using new line transfer

Issue :

Tank product Limited (2 pcs)

Can’t Continue Grinding

Low Base grinding

Can’t reach Target production

Problem solving :

Modification line transfer product (make tank become 3pcs)

Cooperate with Technical Team

Benefit :

Continue grinding

Increase Productivity

Reach Target production

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Increase Base AG1 using new line transfer• Old Facility • New Modification

AG2 TK 101

JET MILL

AG2 TK 201

AG2 TK 301

AG1 TK 101

TUBE MILL

AG1 TK 201

AG1 TK 301

AG2 TK 201

AG1 TK 101

TUBE MILL

AG1 TK 201

AG1 TK 301

AG2 TK 101

JET MILL

AG2 TK 201

AG2 TK 301ABIG

AIL A

NANG PRATAM

A

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

NEXT PLAN IMPROVEMENT 20161. Zero accident Awareness Safety Training

2. Stability Process Adjustment Process & Set parameter

3. Increase percentage Quality on speck Adjustment Process & In-plant analysis

4. Increase Productivity (Quantity)

• AG1

Raw material charging (New Air lifter/Blower). Cooperate with Technical Team

• AG2

Van del hoist Rotor (Replica Rotor) Cooperate with Technical Team

Base up Grinding base (now 0.5t/hr to 1.0t/hr) Trial Production

• AB4

New Facility AB4 Cooperate with Technical Team

AB1/2/3/4 raw material charging & Packing Parallel (Base Up) Trial Production

• AG3

Additional CH New Purchase

Sampling Point TK-122/132/142/152/162/172/182 Cooperate with Technical TeamABIG

AIL A

NANG PRATAM

A

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

NEXT PLAN IMPROVEMENT 2016IMPROVEMENT AG1 AG2 AG3 AB123 ARE ATR AAN

MAN S S S S S S S

MACHINE QtQl

QtQl

QtQl

QtQl

Qt QtQl

QtQl

METHOD St St St Qt St St St

MATERIAL StQt

St St StQt

St St

MONEY Qt QtQl

Qt

S=Safety St=Stability Qt=Quantity Ql =QualityABIG

AIL A

NANG PRATAM

A

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast

Thank you very much for your attentionWe Are Alumina Processing Team

ABIGAIL

ANANG P

RATAMA

PT INDONESIA

CHEM

ICAL

ALUM

INA

@pr

atam

ast