FINAL PROJECT
OPERATIONAL RISK MITIGATION OF PACKING PROCESS IN NAROGONG PLANT 2 PT. HOLCIM INDONESIA, TBK
By: MILA RACHMANIA ID No: 19007067
Undergraduate Program of Management Study School of Business and Management Institut Teknologi Bandung
i
ABSTRACT
Nowadays, manufacture business in Indonesia has grown up in line with national development which always increases every year. The national development is focusing in increasing quality and quantity of national infrastructure. This program is supported by many manufactures company that also have big role which supply raw material so the goal can be reached. Manufacture companies must have some things that hamper its production, especially in operational activity. Operational activity is core activity of a company to run the business and it should be run as well as possible. This research will discuss about operational risk management in packing process. Concerning in many broken machine, maintenance data can be useful to analyze the risk in defining appropriate risk mitigation in this process. To analyze the data, it will use statistic method consist of standard deviation (sigma) and average (mean), also risk scoring and risk mapping. Study case of this research is PT.Holcim Indonesia, which has some process of cement production with its own standard operational procedure with specific material. Each process has special machine and skilled people inside to control result as well. However, there is an unintended thing might be happened when the process is going on that can hamper the activity of cement production. A process that has the biggest probability of fault compared with others is packing process. Packing is one of cement production process consist of the whole activity in cement packaging until the product is ready to be delivered to the consumer. Some fault of this process must cause some risks and directly give negative impact to the company. Therefore, this research will find an appropriate risk treatment to minimize the risk and its impact to the company.
Keywords: Operational Risk, Risk Management, Packing Process
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ABSTRAK Saat ini, bisnis manufaktur di Indonesia telah berkembang sejalan dengan pembangunan nasional yang selalu meningkat setiap tahunnya. Pembangunan nasional saat ini fokus pada peningkatan kualitas dan kuantitas infrastruktur nasional. Program ini didukung oleh banyak perusahaan manufaktur yang juga memiliki peran besar sebagai pemasok bahan baku sehingga tujuan dapat tercapai. Perusahaan manufaktu memiliki beberapa hal yang menghambat kegiatan produksinya, terutama dalam kegiatan operasional. Kegiatan operasional merupakan kegiatan inti dari perusahaan untuk menjalankan bisnis dan harus dijalankan sebaik-baiknya. Penelitian ini akan membahas tentang manajemen risiko operasional dalam proses pengemasan. Dalam kerusakan mesin, data perawatan dapat berguna untuk menganalisis risiko dalam mendefinisikan mitigasi risiko yang tepat dalam proses ini. Dalam menganalisis data, akan digunakan metode statistik yang terdiri dari standar deviasi (sigma) dan rata-rata data (mean), juga risk scoring dan risk mapping. Studi kasus penelitian ini adalah PT.Holcim Indonesia, yang memiliki beberapa proses produksi semen dengan prosedur operasional standar dengan bahan tertentu. Setiap proses memiliki mesin khusus dan orang-orang terampil dalam memantau hasil kerja proses tersebut. Namun, ada hal-hal tertentu dapat terjadi dan menghambat aktivitas produksi semen. Proses yang memiliki probabilitas kerusakan terbesar dibandingkan dengan proses yang lain adalah proses pengepakan. Proses pengepakan merupakan suatu proses produksi semen yang terdiri dari seluruh aktivitas pengepakan semen sampai produk siap untuk dikirim kepada konsumen. Beberapa kesalahan dari proses ini menyebabkan beberapa risiko dan secara langsung memberikan dampak negatif terhadap perusahaan. Oleh karena itu, penelitian ini bertujuan untuk menemukan mitigasi risiko yang tepat untuk meminimalkan risiko dan dampaknya terhadap perusahaan.
Keywords: Resiko Operasional, Manajemen Resiko, Proses Pengepakan
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VALIDATION PAGE
OPERATIONAL RISK MITIGATION OF PACKING PROCESS IN NAROGONG PLANT 2 PT. HOLCIM INDONESIA, TBK
By: MILA RACHMANIA ID No: 19007067
Undergraduate Program of Management Study School of Business and Management Institut Teknologi Bandung
Validated By
_______________________________ Prof. Dr. Sudarso Kaderi Wiryono NIP. 130812294 iv
FOREWORD
First of all, I want to thank God for blessing me in finishing this report so everything well done. Beside my successful in doing this project, there are some people who have important role and always give the best support of them, and I really thankful to all of them. 1. Prof. Dr. Sudarso Kaderi Wiryono. Big thanks for my beloved teacher who always guide and coach me in every step of every part in my final project, also for your patience in leading me during this time. 2. The great family of mine, my Mom and Dad who always give their best support every time I need it. My lovely brother and sister who always company me when I was doing the research. 3. PT. Holcim Indonesia’s employee. My great field mentor, Mr. Edi Sukasmin and Mr. Priyono, you are my new teachers and showed me the new things. Also thanks for Mr. Sigit, Mr. Wahyu, Mr. David Vernanda, Mr. Edi Saptono, Mrs. Lina and others company member who help me in data gathering and giving me the best experience in operational activity. 4. Mr. Danu, Mr. Tezar Saputra, Mr. Arief, Mr. Adi Yudho, Ms. Intan, Mr. Nurbudi, Mrs. Maya, Ms. Manda, Ms. Nita and others SBM mentor who had helped me patiently in explaining, supporting and guiding me every time I had a problem. 5. My Cindils Best Friends,Nabilla Ayumi, Prisca Okke Puriana, Rany Wahyu Larasati, Astari Sirila Sakanti, for the quality time with laughing, loving and caring time together. You guys had given me a great support in your own way. By per-tengil-an and per-cuy-an, those all have made my life colorful. You guys have been my Cindils and always be. Thanks so much! 6. Tri Ruspanji Irwanto, who is a brother, a best friend, a boy friend, a teacher and a mentor for me. Thank you very much for your patience, love, attention to me during this hard time, for being my good listener and good adviser. You’re the best of all !! 7. Esqi & Hendri who helped me in computer software. I don’t know what I would be without your help because I do really ‘gaptek’ in computer program. Also thank you to Dimas Suryo who for his final project as my reference. 8. All SBM students, administrations, staff, three years were not a short time and I do really enjoy being with you along this time. SBM ITB is the best! Bandung, July 10th, 2010 Researcher,
Mila Rachmania v
TABLE OF CONTENTS
TITLE PAGE ........................................................................................................ i ABSTRACT. ......................................................................................................... ii ABSTRAK.............................................................................................................. iii VALIDATION PAGE............................................... ...........................................
iv
FOREWORD..........................................................................................................
v
TABLE OF CONTENTS...... .................................................................................. vi LIST OF FIGURES ............................................................................................. viii LIST OF TABLES
............................................................................................. xii
LIST OF APPENDIXES................................................................... .........................xiii
CHAPTER I INTRODUCTION …………………………………………............. 1 1.1 Background ……………………………………………………............. 1 1.2 Problem Identification…………………………………………............. 2 1.3 Objective Research…………................................................................. 2 1.4 Scope and Limitation………………………………........……............... 3 1.5 Writing Structure………………………………........……..................... 4
CHAPTER II INTRODUCTION................................................................. ........
7
2.1 Risk Concept……………………………………………….................... 7 2.1.1
Operational Risk………………………………………........ 8
2.2 Risk Management………………………………………….................... 10 2.2.1
Risk Identification……………………….……………........ 11
2.2.2
Risk Assessment………………………………………........ 11
2.2.3
Risk Mapping…………………………………….……........ 11
2.2.4
Risk Mitigation………………………………..….…........ 13
CHAPTER III METHODOLOGY……………………………………................... 15 3.1 Research Methodology Chart................................................................. 15 3.2 Research Steps......................................................................................... 16
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CHAPTER IV DATA COLLECTION AND ANALYSIS....................................
19
4.1 Flow Packing Process.............................................................................. 19 4.2 Data Analysis…………………………….............................................. 20 4.3 Risk Categories........................................................................................ 43 4.4 Risk Mapping........................................................................................... 48 4.5 Risk Mitigation........................................................................................ 50 4.5.1
Risk Avoid
.......... ...................................................
50
4.5.2
Risk Transfer………………………………………............ 51
4.5.3
Risk Control……………………………………….............. 51
4.5.4
Risk Retain…………………………………………...…...... 52
CHAPTER V CONCLUSION AND RECOMMENDATION................................ 53 5.1 Conclusion………………………………………................................... 53 5.2 Recommendation for PT.Holcim Indonesia......................................... 54 5.3 Recommendation for Further Research...............................................
54
REFERENCES ……………………………………………………………............. 55 APPENDICES........................................................................................................... 56
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LIST OF FIGURES
Figure 1 Scope and Limitation................................................................................... 3 Figure 2 Risk Management Goals …………………................................................ 8 Figure 3 Risk Management Cycle............................................................................. 10 Figure 4 Risk Mapping……………………....… ………………………................. 12 Figure 5 Research Steps ………………………………………………………….... 13 Figure 6 Flow Chart Methodology ……………………………………………....... 15 Figure 7 Adjust Recipe Frequency ………………….………................................ 23 Figure 8 Air Plant Frequency .........................................................................
23
Figure 9 Bag Guide Adjust Frequency ……………………………………............. 23 Figure 10 Bag Holder Trouble Frequency................................................................ 23 Figure 11 Bag Cleaner Frequency …………………................................................ 23 Figure 12 Barcode Error Frequency.......................................................................... 23 Figure 13 Baut Adjustment Frequency …………………………………………..... 24 Figure 14 Bearing Rusak Frequency ……………………………………………... 24 Figure 15 Box LM Panel Jatuh Frequency ……………………………………...... 24 Figure 16 BF Stuck Frequency ………………….………....................................... 24 Figure 17 Belt Trouble Frequency
.............................................................
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Figure 18 Brake Tidak Normal Frequency ……………………………….............. 24 Figure 19 Breaker Frequency................................................................................... 25 Figure 20 Buka Angin Bag Filter Frequency …………………............................... 25 Figure 21 Butterfly Trouble Frequency.................................................................... 25 Figure 22 Cable Putus Frequency …………………….………………………........ 25 Figure 23 Compressor Rusak Frequency ……………………………...…………... 25 Figure 24 Connector Trouble Frequency ………………………………………..... 25 Figure 25 Contact MC Rusak Frequency ………………......................................... 26 Figure 26 Cover Rotor Blade Perbaikan Frequency .........................................
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Figure 27 CV 69 Eror Frequency …………………………………………............. 26 Figure 28 Evakuasi Tidak Normal Frequency......................................................... 26 Figure 29 Flushing DC Frequency …………………................................................ 26 Figure 30 Gate Stuck Frequency............................................................................... 26 Figure 31 Komunikasi Eror Frequency ………………………………………….....27 viii
Figure 32 Motor Trouble Frequency ……………………………………………... 27 Figure 33 NFB Trouble Frequency
...............................................................
27
Figure 34 Packer Trouble Frequency ……………………....................................... 27 Figure 35 Perb Push Button Frequency.................................................................... 27 Figure 36 Perb CG2 Frequency ………………….................................................... 27 Figure 37 Perbaikan 636DV4 Alarm Frequency...................................................... 28 Figure 38 Perb Flexible 66B SN2 Frequency …………………….…….……........ 28 Figure 39 Pipa Patah Frequency …………………………………………………... 28 Figure 40 Perbaikan Feder Pallet Frequency ……………………..……………..... 28 Figure 41 Piston Trouble Frequency ………………................................................ 28 Figure 42 Plate Perbaikan Frequency ...............................
...............................
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Figure 43 PLC Eror Frequency ……………………………………………............. 29 Figure 44 Pneum Rusak Frequency........................................................................... 29 Figure 45 Rantai Trouble Frequency …………………............................................ 29 Figure 46 Regulator Rusak Frequency...................................................................... 29 Figure 47 Relay Emergency Frequency …………………………………………... 29 Figure 48 Roller Trouble Frequency ..............................................................
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Figure 49 Sadle Bag Trouble Frequency ………………………………….............. 30 Figure 50 Safety Guide Trouble Frequency............................................................. 30 Figure 51 Seal Bocor Frequency ………………….................................................. 30 Figure 52 Selang Trouble Frequency........................................................................ 30 Figure 53 Sensor Trouble Frequency …………………….…………………........ 30 Figure 54 Setting Device Frequency ………………………………..……………...30 Figure 55 Setting Parameter Frequency ………………………………..………..... 31 Figure 56 Shifter Trouble Frequency ………………............................................... 31 Figure 57 Slide Gate Trouble Frequency
......................................................
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Figure 58 Solenoide Frequency …………………………………...………............. 31 Figure 59 Speed Eror Frequency............................................................................... 31 Figure 60 Sproket Trouble Frequency ……………………….…............................ 31 Figure 61 Test on Vento Check Frequency.............................................................. 32 Figure 62 Test Running Frequency .................................................................
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Figure 63 Timbangan Fluktuasi Frequency............................................................... 32 Figure 64 Tube Trouble Frequency ………………….............................................. 32 ix
Figure 65 V Belt Aus Frequency............................................................................... 32 Figure 66 Adjust Recipe Loss …………………….………………………..…........ 36 Figure 67 Air Plant Loss
.....................................................
...................
36
Figure 68 Bag Guide Adjust Loss …………………………………………............. 36 Figure 69 Bag Holder Trouble Loss......................................................................... 36 Figure 70 Bag Cleaner Loss …………………......................................................... 36 Figure 71 Bearing Rusak Loss.................................................................................. 36 Figure 72 Baut Adjustment Loss ………………………………………………...... 36 Figure 73 Barcode Eror Loss ……………………………………………………... 36 Figure 74 BF Stuck Loss ………………………………………………….……..... 37 Figure 75 Belt Trouble Loss ……………………….....………................................ 37 Figure 76 Breaker Loss ....... ........... ........... ........... ........... ........... ..................... 37 Figure 77 Break Tidak Normal Loss ..................... ........... ......... ........... .......... 37 Figure 78 Box LM Panel Jatuh Loss..........................................................................37 Figure 79 Buka Angin Bag Filter Loss …………………………............................. 37 Figure 80 Butterfly Trouble Loss.............................................................................. 37 Figure 81 Cable Putus Loss ……………………………..……………………........ 37 Figure 82 Compressor Rusak Loss
...................................................................... 38
Figure 83 Connector Trouble Loss …………………………………..…………..... 38 Figure 84 Contact MC Rusak Loss ……………….................................................. 38 Figure 85 Cover Rotor Blade Perbaikan Loss.....................................................
38
Figure 86 CV 69 Eror Loss
38
...............................
....................
....................
Figure 87 Evakuasi Tidak Normal Loss................................................................... 38 Figure 88 Flushing DC Loss …………………....................................................... 38 4Figure 89 Gate Stuck Loss.................................................................................... 38 Figure 90 Komunikasi Eror Loss ……………………………..….……………..... 39 Figure 91 Motor Trouble Loss ……………………………...…..…..……………... 39 Figure 92 NFB Trouble Loss .......... ......... .............................................. ........... 39 Figure 93 Packer Trouble Loss ……………………………………………............. 39 Figure 94 Pipa Patah Loss......................................................................................... 39 Figure 95 Perb Push Button Loss ……………………………............................... 39 Figure 96 Perbaikan CG2 Loss................................................................................. 39 Figure 97 Perb Flexible 66B SN2 Loss …………………..…………….……........ 39 x
Figure 98 Perbaikan 636DV4 Alarm Loss……………………………………...
40
Figure 99 Perbaikan Feder Pallet Loss ………………………….……………..... 40 Figure 100 Piston Trouble Loss ....... .......... ........... ............................................. 40 Figure 101 Plate Perbaikan Loss
................................
.......... ........... .......... 40
Figure 102 PLC Eror Loss........................................................
.................
40
Figure 103 Pneum Rusak Loss................................................................................. 40 Figure 104 Rantai Trouble Loss ………………….................................................. 40 Figure 105 Regulator Rusak Loss.............................................................................. 40 Figure 106 Relay Emergency Loss ………………………………………………... 41 Figure 107 Roller Trouble Loss
............................................
...................... 41
Figure 108 Sadle Bag Trouble Loss …………………………………….….............41 Figure 109 Safety Guide Trouble Loss..................................................................... 41 Figure 110 Seal Bocor Loss …………………………………….............................. 41 Figure 111 Selang Trouble Loss................................................................................ 41 Figure 112 Sensor Trouble Loss ……………………………………….……........ 41 Figure 113 Setting Device Loss ………………………………….………………... 41 Figure 114 Setting Parameter Loss …………………………………..…………..... 42 Figure 115 Shifter Trouble Loss ………………..............................................
42
Figure 116 Slide Gate Trouble Loss .......... .......... .......... ........... ....................
42
Figure 117 Solenoide Loss................................................................................
42
Figure 118 Speed Eror Loss...................................................................................
42
Figure 119 Sproket Trouble Loss …………………………….…............................ 42 Figure 120 Test on Vento Check Loss....................................................................... 42 Figure 121 Test Running Loss .................................. ....................................... Figure 122 Timbangan Fluktuasi Loss......................................................
42
.......... 43
Figure 123 Tube Trouble Loss …………………..................................................... 43 Figure 124 V Belt Aus Loss ........... ..........................................
......... ........... 43
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LIST OF TABLE Table 1
Risk Event Frequency............ ...................................
....................
22
Table 2
Potential Loss Caused by Idle Time...................................................... 33
Table 3
Potential Loss Caused by Maintenance................................................ 34
Table 4
Total Potential Loss................... ...........................................
Table 5
Classification of Frequency…………………........................................ 44
Table 6
Classification of Severity……………………………………………… 45
Table 7
Risk Events Category……………………….…………….................... 47
Table 8
Risk Control............................................................................................ 51
Table 9
Risk Retain.............................................................................................. 52
........... 35
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LIST OF APPENDICES APPENDIX 1 FLOW PROCESS CHART............................................................... 57 APPENDIX 2 RISK EVENT AND POTENTIAL LOSS....................................... 66
xiii
