PT. PRIKAST METAL INDONESIA Rep No : 01-PMI-2015
MONTHLY REPORT OKTOBER 2015 Dep/Sec : Company
Date : 10-Nov-15
MONTHLY REPORT
OCTOBER 2015
PT. PRIKAST METAL INDONESIA
PT. PRIKAST METAL INDONESIA Rep No : PMI-X-2015
MONTHLY REPORT OKTOBER 2015 Dep/Sec :
Date : October
DAFTAR ISI
1
1 Laporan PPIC 2
1.1 Load VS Capasity of Disa Moulding 3
1.2 load VS Capasity of Core Machine 4
1.3 Plan VS Actual Production of Disa Moulding 5
1.4 Delivery Achievement 5
5
1.5 Data of Pareto Out Standing
1.6 MRP VS Actual Scrap Auto 6
1.7 MRP VS Actual Scrap Non Auto 8
9
2 Laporan Production 10
2.1 Report Disa Machine 11
2.2 data Material Usage 12
2.3 Report Core Machine 13
2.4 Lampiran 14
16
3 Warehouse 17
3.1 Monthly Report Warehouse 18
4 PGA 19
4.1 Overtime Oktober 23
4.2 PAM dan AIR
30
5 Quality
5.1 Rejection Rate Disa 2015 34
5.2 Sand Related Defect Foundry Report 36
5.3 Sand Related Defect Machining Report 37
5.4 Sand Properties & Komposisi Pasir Disa 38
40
6 Product Engineering
6.1 Progress Production Development 41
6.2 Schedule by Customer 41
41
7 Process Enginering
7.1 Evaluasi Pemakaian Material Charging October 42
43
8 Maintenance
8.1 Losetime Machine
8.2 Detail Problem Machine
8.3 Report problem mesin dan action perbaikan nya
8.4 Job desc Team Maintenance
8.5 Suggestion System Oktober
9 P2K3L
9.1 Data Kecelakaan Kerja
9.2 Man Hours Loss
9.3 Hospital Cost
10 Purchasing
10.1 Rekap Pembelian October
10.2 Rekap Pembelian Agustus - Oktober
PRODUCTION ACHIEVMENT REPORT Ref No : P-01-PMI-X-2015
YEAR 2015 Dept : Production PPIC
Month : October
Hours 1.1 Load vs Capacity of DISA Moulding
450
400
350
300 Loading
2 Shift ( 15H )
250 1 Shift ( 8H )
3 Shift ( 22H )
200
150
100
50
0
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Work Eff = 85 %
Working Days 21 Satuan
6 21 21 21 143 Days
268 Hours
1 Shift ( 8H ) 41 143 143 143 393 Hours
2 Shift ( 15H ) Hours
Capacity 77 268 268 268 Hours
3 Shift ( 22H ) 112 393 393 393
Loading
58 205 192
Remarks : Loading bulan oktober = 72% dari kapsitas 2 Shift
Mould Load vs Capacity of DISA Moulding Loading
1 Shift ( 8H )
50000 2 Shift ( 15H )
45000 3 Shift ( 22H )
40000
35000
30000
25000
20000
15000
10000
5000
0
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Out Put/Hour = 113 Mould
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Satuan
Working Days
6 21 21 21 21 Days
1 Shift ( 8H )
Capacity 2 Shift ( 15H ) 4610 16136 16136 16136 16136 Mould
3 Shift ( 22H ) 8645 30256 30256 30256 30256 Mould
Loading
12679 44375 44375 44375 44375 Mould
6520 23186 21659 Mould
Kg Load vs Capacity of DISA Moulding Loading
1 Shift ( 8H )
600000 2 Shift ( 15H )
3 Shift ( 22H )
500000
400000
300000
200000
100000
0
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Satuan
Working Days Days
6 21 21 21 21 Kg
1 Shift ( 8H ) Kg
Capacity 2 Shift ( 15H ) 52515 183804 183804 183804 183804 Kg
Kg
3 Shift ( 22H ) 98467 344633 344633 344633 344633
Loading 1
144418 505462 505462 505462 505462
85359 271260 237859
PRODUCTION ACHIEVMENT REPORT Ref No : P-01-PMI-X-2015
YEAR 2015 Dept : Production PPIC
Month : October
Hours 1.2 Load vs Capacity Of Core Machine H. Mould
MC 6
1.800 MC 5
1.600 MC 4
1.400 MC 3
1.200 MC 2
1.000 MC 1
1 Shift
800 2 Shift
600 3 Shift
400
200 Satuan
Days
- Hours
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Hours
Hours
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
8 21 21 21 21
Working Days 218 571 571 571 571
408 1071 1071 1071 1071
Capacity 1 Shift 598 1571 1571 1571 1571
2 Shift 56 84 119
115 71
3 Shift 47 115 105
43 93 3
MC 1 82 2 1
0 55 54
MC 2 0 214 202
51
Loading MC 3
MC 4
MC 5
MC 6
H. Mould
Remarks :
Load Vs Capacity each Core Machine
350 71 105 3 1 54 202
300 MC 2 MC 3 MC 4 MC 5 MC 6 HM
250
200 2
150
100 119
50
0
MC 1
Loading Capacity
Description MC 1 MC 2 MC 3 MC 4 MC 5 MC 6 HM SATUAN
1 1 1 1 1 1 2 Org
Capacity Qty of M/P Hours
1 Shift ( 8 H ) 149,6 149,6 149,6 149,6 149,6 149,6 299,2 Hours
119 71 105 3 1 54 202
Loading
Remarks :
PRODUCTION ACHIEVMENT REPORT Doc No : P-01-PMI-X-2015
YEAR 2015 Dept : Production
Month : October
Mould 1.3 Plan vs Actual Production of DISA Moulding %
35000 136% 143% 160%
30000 140%
25000 109% 120% Plan Prod
20000 100% Actual
15000 80% Percentage ( % )
10000 60%
0% 0% 0% 0% 0% 0% 0% 40%
5000 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV 20%
0 0%
DEC
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Satuan
Plan Prod 14907 Mould
0 0 0 0 0 0 0 6520 23186 21379 Mould
Actual 6472 Mould
Different 0 0 0 0 0 0 0 7085 31603
Percentage ( % ) 143 %
0 0 0 0 0 0 0 565 8417
109 136
Kg %
Plan vs Actual Production of DISA Moulding 160%
140%
400000 135% 140% 120%
350000 100%
300000 115% 80% Plan Prod
250000 60% Actual
200000 40% Percentage ( % )
150000 20%
100000 0% 0% 0% 0% 0% 0% 0% 0%
JAN FEB MAR APR MAY JUN JUL DEC
50000
0
AUG SEP OCT NOV
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Satuan
Plan Prod 0 Kg
0 0 0 0 0 0 0 85359 271260 185535 Kg
Actual Kg
Different 0 0 0 0 0 0 0 98208 366828 259233 %
Percentage ( % )
0 0 0 0 0 0 0 12849 95569 73698 0
115 135 140
Hours Plan vs Actual of Production Working Time %
350 133% 147% 160%
300 140%
250 129% 120%
200 100%
150 0% 0% 0% 0% 0% 0% 0% AUG SEP OCT NOV 80% Plan Prod
100 JAN FEB MAR APR MAY JUN JUL 60% Actual
40% Percentage ( % )
50 MAY 20%
0 0 0% Satuan
0 DEC Hours
Note : 0 Hours
Hours
Description JAN FEB MAR APR JUN JUL AUG SEP OCT NOV DEC
Plan Prod 0000 00 68 233 143 %
0000 00 90 300 210 00
Actual 0000 00 23 68 68 3
Different 133 129 147
Percentage ( % )
Ket :
PRODUCTION ACHIEVMENT REPORT Doc No : P-01-PMI-X-2015
YEAR 2015 Dept : Production
Month : October
Pcs 1.4 Delivery Achievement
PURCHASE ORDER
70000 OUT STANDING
ACTUAL
60000 46814
50000 43982
40000
30000
20000
10000
0 0 0 0 0 0 0 2322
0
1 2 3 4 5 6 7 8 9 10 11 12
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Satuan
OUT STANDING Pcs
PURCHASE ORDER 23207 19198 3794 Pcs
Pcs
TOTAL 2322 47354 43804 Pcs
ACTUAL Pcs
DIFFERENT 25529 66552 47598 %
DELIVERY ACHIEVEMENT
2322 46814 43982
Remarks :
-23207 -19738 -3616
9 70 92
Kg
Delivery Achievement
400000 301386
350000
300000 258355 OUT STANDING
250000 PURCHASE ORDER
200000 ACTUAL DELIVERY
150000
100000 0 0 0 0 0 0 929
JAN FEB MAR APR MAY JUN
50000 0
0 JUL
AUG SEP OCT NOV DEC
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Satuan
OUT STANDING 9283 7679 5921 Kg
PURCHASE ORDER 76076 360867 335905 Kg
85359 368547 341826 Kg
TOTAL 929 258355 301386 Kg
ACTUAL DELIVERY -84430 -110192 -40440 Kg
70 89 %
DIFFERENT 1
Percentage (%) 4
Remarks :
Delivery Achievement = 89 % ( Not Achievement ) caused un balance capacity between Disa Moulding vs Finishing
PRODUCTION ACHIEVMENT REPORT Doc No : P-01-PMI-X-2015
YEAR 2015 Dept : Production
Month : October
1.5 Data of Pareto Out Standing
Pcs
936 1049 Out Standing
1200
1000 213 605 375 456
1692 160 768
800
600
400
200
0
1716 441 1478 1479 735
Description Parts Number Total Satuan
Out Standing
1692 1716 441 1478 1479 735 768 3794 Pcs
213 936 375 456 40440 Kg
85.2 7488 160 605 1049 4339 1596 %
24 10 12 100
6 992 9680 16259.5
4 16 28
Remarks : * Out Standing problem : 1. Quality of Casting ( Out Standard ) ===> Over dimension, Cross Joint & Bad Core
2. Additional working ( Repaired parts from Sub - Cont )
3. Requirement of Grinding wheel
Kg %
250,000 MRP VS Actual Scrap Auto
200,000
350%
284% 322% 300%
150,000 165% 250% MRP
100,000 200% Actual
150% Percentage %
100%
50,000 50%
- 0% 0% 0% 0% 0% 0% 0% 0 0% 0% 0%
1
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DES Satuan
MRP 0% 0% 0% 0% 0% 0% 0%
Actual 33,510 77,705 45,718 Kg
Diff MRP vs Actual 55,204 220,483 147,350 Kg
Percentage %
21,694 142,778 101,632 Kg
Remarks :
165% 284% 322% %
Kg MRP VS Actual Scrap Non Auto %
100000 101% 129% 140%
90000 92% 120%
80000 100%
70000 80% MRP
60000 60% Actual
50000 40% Percentage %
40000 20%
30000 0% 0% 0% 0% 0% 0% 0% 0%
20000 1
10000
0
Description JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Satuan
MRP
Actual 38933 86147 49946 Kg
Diff MRP vs Actual 0 0 0 0 0 0 0 35794 87037 64249 Kg
Percentage %
-3139 890 14303 Kg
Remarks :
0% 0% 0% 0% 0% 0% 0% 92% 101% 129% 0% 0% %
5
PRODUCTION ACHIEVMENT REPORT Doc No : P-02-PMI-X-2015
YEAR 2015 Dept/Sec : Production
Month : October
% 2.1 Report Disa Machine Working Efficiency of Disa Machine
100
90
80
70
60 Actual
Target
50
40
30
20
10
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Description Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Satuan
%
Target 95 95 95 %
Actual 55.29
Remarks : Achivement of working efficiency = 56 % caused there were reducing order from customer
% Production Efficiency of Disa Machine
90 Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Actual
80 Jan Feb Mar Apr May Jun Target
70 Jul Aug Sep Oct Nov Dec
60 Satuan
50 85 85 85 %
40 %
30 84.27
20
10
0
Jan
Description
Target
Actual
Remarks :
% Feb Net Operation Time of Disa Machine Actual
Target
90 Mar Apr May Jun Jul Aug Sep Oct Nov Dec
80 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Satuan
70 %
60 82.95 %
50
40
30
20
10
0
Jan
Description Dec
Target
Actual
Remarks :
Mnt 2 Cycle Time of Disa Machine Actual
35 Target
30 3 4 5 6 7 8 9 10 11 12
25 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Satuan
20 Mnt
15 30 30 Mnt
10 28.8
5
0
1
Description Dec
Target 30
Actual
Remarks :
6
% PRODUCTION ACHIEVMENT REPORT Doc No : P-02-PMI-X-2015
YEAR 2015 Dept/Sec : Production
2.5 Month : October
Preparation Time of Disa Machine
2 Actual
Target
1.5
Feb Mar Apr May Jun Jul Aug Sep Des Satuan
1 %
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov %
0.5 2
0 1.42
Jan
Description
Target
Actual
Remarks :
Pcs Production Achievement of Disa Machine ( Output/ Hour ) Actual
Target
140 Feb Mar Apr May Jun Jul Aug Sep Oct Nov
120 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Des Satuan
100 108 108 108 Pcs
86 107 123 Pcs
80
60
40
20
0
Jan
Description
Target
Actual
Remarks :
Mnt Date of Down Time of Disa Machine Actual
Target
16
14 Des Satuan
12 Mnt
10 Mnt
8
6
4
2
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct
Description Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov
Target 15
15.02
Actual
Remarks : Actual of total down time higher than actual caused : Not yet standard of volume hill for each furnace
New std volume hill for each furnace ==> F-01 = 500 Kg , F-02 = 2000 Kg , F-03 = 2000 Kg ( New standard from engineering )
% Breakdown of Down Time
7 Actual
6 Target
5
4 234 56 7 8 9 10
3 GF GS GP
2 GM GB GOP 0 3.31 0 GQ LP GTr Satuan
1
0 %
1 4.17 6.49 0 0.16 0.88 0 %
Description
Target
Actual
Remarks :
7
PRODUCTION ACHIEVMENT REPORT Doc No : P-02-PMI-X-2015
YEAR 2015 Dept/Sec : Production
Month : October
Kg 2.2 Data of Material Usage ( Scrap Auto ) Actual
Plan
160
140
120
100
80
60
40
20
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct
Description Jan Feb Mar Apr May Jun Jul Aug Sep Oct Satuan
Plan 70.8 Kg
144 Kg
Actual
Remarks : Actual using of scrap auto higher than planing caused volume of material hill at each furnace always less than standard
Plan of material usage base on engineering standard.
Kg Data of Material Usage ( Non Auto / Kawat ) Actual
Plan
90
80 Sep Oct
70
60 Oct Satuan
50 77.12 %
40 62.49 %
30
20
10
0
Jan Feb Mar Apr May Jun Jul Aug
Description Jan Feb Mar Apr May Jun Jul Aug Sep
Plan
Actual
Remarks : Plan of material usage base on engineering standard.
Kg Data of Material Usage ( Return / Gating )
300 Feb Mar Apr May Jun Jul Aug Sep Oct Actual
250 Jan Feb Plan
200 Mar Apr May Jun Jul Aug Sep Oct Nov Des
150 222.8 Satuan
100 238.3 %
%
50
0
Jan
Description
Plan
Actual
Remarks :
8
PRODUCTION ACHIEVMENT REPORT Doc No : P-02-PMI-X-2015
YEAR 2015 Dept/Sec : Production
Month : October
Pcs %
2.3 Production Achievement of Core Machine 80%
74%
45000 Plan
40000 70% Actual
35000 60% Percentage
30000 50%
25000 0% 0% 0% 0% 0% 0% 0% 0% 0% 40%
20000 Jan Feb Mar Apr May Jun Jul Aug Sep 30%
15000 20%
10000 10%
0%
5000 Oct
0
Description Jan Feb Mar Apr May Jun Jul Aug Sep Oct Satuan
Plan 41008 Pcs
Actual 30533 Pcs
74% %
Percentage
Remarks :
Pcs Production Achievement of Finishing %
35000 90%
30000 80%
25000
20000 70%
Target
60%
Actual
50% Percentage
15000 40%
10000 30%
20%
5000 10%
0 0%
Jan Feb Mar Apr May Jun Jul Aug Sep
Description Jan Feb Mar Apr May Jun Jul Aug Sep Nov Des Satuan
Target
29135 Pcs
Actual 22488 Pcs
Percentage 77% %
Remarks : Actual total output less than target caused shortage of grinding requierment
9
DEFINITION OF PRODU
2.4 Lampiran Istilah WORKIN
Prep. Time ( PrT ) Productive Time ( PT )
Net Operation Time ( NOT )
79%
1. Working Time ( WT ) ( Prod ) : Jam kerja reguler
2. Productive Time ( PT ) ( Prod ) : Waktu yang effective digunakan untuk melakukan aktivitas kerja
3. Un Productive Time ( UPT ) ( Prod ) : Waktu yang tidak menghasilkan output
4. Preparation Time ( PrT ) ( Prod ) : Waktu yang dibutuhkan untuk persiapan proses produksi
5. Net Operation Time ( NOT ) ( Prod ) : Waktu yang murni dapat menghasilkan output ( Real Capacity )
6. Down Time ( DT ) : Hambatan yang timbul pada saat proses produksi berjalan
* Gangguan mesin ( GM ) ( MTC ) : Waktu yang hilang karena adanya kerusakan mesin
* Gangguan bahan ( GB ) ( Prod ) : Waktu yang hilang karena menunggu kesiapan material
* Gangguan operational ( GOP ) ( Prod ) : Waktu yang hilang karena operator belum siap memulai pekerjaan
* Gangguan Forklift ( GF ) ( Prod ) : Waktu yang hilang karena menunggu forklift
* Gangguan Sarana ( GS ) ( Prod/MTC ) : Waktu yang hilang karena adanya gangguan sarana ( Crane,
* Gangguan Pallet ( GP ) Compressor,Conveyor, Ladle, ganti batu grinda )
* Gangguan Quality ( GQ ) ( Prod ) : Waktu yang hilang karena menunggu kesiapan / tidak ada pallet
* Listrik Padam ( LP ) ( QC ) : Waktu yang hilang karena adanya pengecekan hasil produksi
* Gangguan Trial (GTr) ( MTC ) : Waktu yang hilang karena aliran listrik padam
( Eng ) : Waktu yang hilang karena ada kegiatan trial
7. Idle Tme ( IT ) ( All ) : Waktu yang hilang karena adanya kegiatan yang direncanakan
* Apel Pagi ( AP ) ( Prod ) : Waktu yang hilang karena adanya kegiatan apel pagi
* Morning Talk ( MT ) ( All ) : Waktu yang hilang karena adanya kegiatan breafing
* Coffee Break ( CB ) ( Prod ) : Waktu yang hilang karena adanya kegiatan coffee break
* Kegiatan kebersihan ( 5S ) : Waktu yang hilang karena adanya kegiatan 5S
* Gangguan Order (GO) ( PPC ) : Waktu yang hilang karena tidak ada loading
UCTION WORKING TIME
NG TIME ( WT )
Un Productive Time ( UPT ) Idle Time ( IT )
Down Time ( DT )
GM GB GOP GF GS GP GQ LP GTr AP MT CB 5S GO
Working Effisiency Productive Time ( PT )
Productivity = X 100% = …………. %
Cycle Time
Pass Rate Working Time ( WT )
Repair Rate
Net Operation Time ( NOT )
Rejection Rate = X 100% = …………. %
Working Capacity
Production Capacity Working Time ( WT )
Net Operation Time ( NOT ) = …………. Mnt
=
Total Out Put
Total Parts OK
= X 100% = …………. %
Total Out Put
Total Parts Repair
= X 100% = …………. %
Total Out Put
Total Parts NG
= X 100% = …………. %
Total Out Put
= WH x WD x QM x WE = ………….Hours
= WH x WD x QM x WE x Output/H x Qty/Cavity = …………. Pcs
= Prod Capacity (Pcs) x Weight/Pcs = …………. Kg
Note : WH : Working Hours QM : Quantity of Machine
WD : Working Day's WE : Working Efficiency
10
Form Production - Prod 1
PT. PRIKAST METAL INDONESIA Rev No : P-03-PMI-X-2015
MONTHLY REPORT OCTOBER 2015 Dept :
Date : Prod/Warehouse
Oktober
Berikut grafik 5 besar material consumable dan total cost tertinggi:
3.1.Grafik Material In - Out Bulan Oktober
Grafik Material In - Out
1P6#0,A00U0# STEEL SCRAP STEEL SCRAP MAGNESIUM CARBURIZER RCS KH
1P4#0N,0O00# AUTO NON AUTO DENODUL (GPC)
M120D,0E00N 46,000
108#00,,000000# 143,281 80,141 4,800 8,000 46,800
6#0,000#
40,000 147,350 64,249 4,300 7,700
20,000
-
IN
OUT
3.2.Harga Material Consumable UNIT IN OUT HARGA(Rp) TOTAL Out(Rp)
744,117,500.00
NO. DESKRIPSI KG 143,281 147,350 5,050 Rp 256,996,000.00
KG 80,141 137,600,000.00
1 STEEL SCRAP AUTO KG 4,800 64,249 4,000 Rp 110,110,000.00
2 STEEL SCRAP NON AUTO KG 8,000 92,430,000.00
3 MAGNESIUM DENODUL KG 46,000 4,300 32,000 Rp
4 CARBURIZER (GPC)
5 RCS KH 7,700 14,300 Rp
46,800 1,975 Rp
Rp800,000,000.00 IN
OUT
Rp700,000,000.00
STEEL MAGNESI CARBURIZ RCS KH
Rp600,000,000.00 SCRAP UM ER (GPC)
NON
Rp500,000,000.00 AUTO DENODUL
Rp400,000,000.00
Rp300,000,000.00
Rp200,000,000.00
Rp100,000,000.00
Rp-
STEEL
SCRAP
AUTO
NO. DESKRIPSI Total In TOTAL Out(Rp)
1 STEEL SCRAP AUTO Rp 723,569,050.00 Rp 744,117,500.00
2 STEEL SCRAP NON AUTO
3 MAGNESIUM DENODUL Rp 320,564,000.00 Rp 256,996,000.00
4 CARBURIZER (GPC)
5 RCS KH Rp 153,600,000.00 Rp 137,600,000.00
Rp 114,400,000.00 Rp 110,110,000.00
Rp 90,850,000.00 Rp 92,430,000.00
11
PT. PRIKAST METAL INDONESIA Rep No : G-04-PMI-X-2015
MONTHLY REPORT OKTOBER 2015 Dep/Sec : Company
Date :
NILAI (Rp) 10-Nov-15
4.1 Perhitungan Overtime October
35000000 NILAI (Rp)
30000000
25000000
20000000
15000000
10000000
5000000
0
MELTING CORE PEMATAH POURING TRIMING SHB FINISHING MAINT QUALITY ENG GA WH PPC PURCNG FIN
JAM
1600 JAM
1400
1200
1000
800
600
400
200
0
MELTING CORE PEMATAH POURING TRIMING SHB FINISHING MAINT QUALITY ENG GA WH PPC PURCNG FIN
OT OKTOBER
MELTING CORE PEMATAH POURING TRIMING SHB FINISHING MAINT QUALITY ENG GA WH PPC PURCNG FIN
530 358.5 128.5 277 1590.5 450 102.5 309 246 28 13
JAM 576.5 703.5 8,736,671 288.5 1064.5 32,859,636 12,179,018 2,381,422 6,826,824 5,590,876 794,324 232,948
11,149,514 8,206,488 3,466,601
NILAI (Rp) 13252960 14,028,569 5,674,653 24,838,197
12
4.2 Perhitungan Pam dan Listrik PT. PRIKAST METAL INDONESIA Ref No : G-04-PMI-X-2015
MONTHLY REPORT OKTOBER 2015 Dep/Sec : HR/GA
Date : October
Pemakaian PAM
STAND AWAL
10000000 STAND AKHIR
8000000 BIAYA
6000000
4000000 6
2000000
0
12345
BULAN AGUSTUS SEPTEMBER OKTOBER
STAND AWAL 8535970 3080
STAND AKHIR 3851
BIAYA 9828620
LISTRIK
1000.000.000 Biaya
900.000.000
800.000.000
700.000.000
600.000.000
500.000.000
400.000.000
300.000.000
200.000.000
100.000.000
0
BULAN AGUSTUS SEPTEMBER OKTOBER
BULAN PEMBAYARAN
AGUSTUS
SEPTEMBER 489.487.860
OKTOBER 901.978.008
693.800.341
13
PT. PRIKAST METAL INDONESIA Ref No : Q-05-PMI-X-2015-05-
MONTHLY QUALITY REPORT Dep/Sec. : QUALITY
Date : Oktober 2015
5.1 REJECTION RATE DISA 2015
25
20
Kg 15 13,62
%
10 8,81
5 3,91
0 Jan Feb Mar Apr Mei Jun Jul Agust Sep Okt Nop Des YTD
2014 PMI
Foundry 3,91 65,,7427 95,,266
M/C. Shop 3,91 8,81 13,62
Total Reject
Target 6,0 6,0 6,0 6,0 6,0 6,0 6,0 6,0 6,0 6,0 6,0 6,0 6,0
Bench Mark 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0 4,0
Total Plant
Pada bulan Oktober reject meningkat menjadi 13,62%. Reject foundry meningkat menjadi 9,26% , sedangkan reject machining
menurun menjadi 5,6%.
Inspection vs Rejection (Kg)
500000
450000
400000
350000 320.025,18
235220
300000
250000
200000
150000
100000 75736,23
50000 32040
2960,5812.008,2
0 2014 Jan Feb Mar Apr Mei Jun Jul Agust Sep Okt Nop Des YTD
PMI
Inspect
Reject 75736,2 320.025 235220
2960,58 12.008, 32040
Casting yang diinspeksi pada bulan Oktober lebih sedikit dibandingkan September, namun menghasilkan reject lebih banyak
yaitu 32040 kg.
14
100,01% PT. PRIKAST METAL INDONESIA Ref No : Q-05-PMI-X-2015
80,01% MONTHLY QUALITY REPORT Dep/Sec. : QUALITY
60,01% Date : Oktober 2015
40,01% PARETO REJECT
20,01% 120,00%
100,00%
80,00%
60,00%
40,00%
20,00%
0,01% 768 1479 1478 735 441 0,00%
6,11% 7,04%
%Reject 2,11% 3,46% 4,07% 69,11% 100,00% SI
GH
%kumulatif 9,26% 24,44% 42,30% SKG
MS
Remarks/Explanation: SL
CRS
Hasil inspeksi hard inspect, reject terbesar terdapat pada BT 441 sebesar 7.04% Scab
BC
PARETO ALL REJECT MRT
BCR
100 OG
BM
90
80
70
60
50
40
30
20
10
0 441 735 768 1478 1479
SI 180 45 77 99 120
GH 1 1
SKG 5 271
MS 49 3 12 1
SL 12 3 4 19 9
CRS 17
Scab 1
BC 29 3 5 11 4
MRT 5 2 2
BCR 1
OG 2 1 62 1
BM 3 7 1 2 3
Remarks/Explanation:
Hasil inspeksi hard inspect, reject terbesar yang dihasilkan setiap produk adalah reject sand inclusion.
SI = Sand Inclusion SCB = Scab 15
GH = Gas BC = Broken Casting
SKG = ShrinHkaoglee MRT = Mould Retak
MS = Misrun BCR = Bad Core
SL = Slag OG = Over Gerinda
CRS = Crash BM = Bad Mould
PT. PRIKAST METAL INDONESIA Ref No : Q-05-PMI-X-2015
MONTHLY QUALITY REPORT Dep/Sec. : QUALITY
5.2 SAND RELATED DEFECT FOUNDRY REPORT Date : Oktober 2015
Sand Related Defect Foundry Jan - Des 2015
4
3
Procentage (%) 2
1
0 Jan Mar April Mei Jun Jul Agu Sep Okt
%0
1,56 3,2 2,85
Reject yang disebabkan karena pasir mengalami penurunan pada bulan Oktober menjadi 2,85%.
Percentage Inspect ( Kg ) vs Kg Reject SRD Oktober 2015
12,00%
20000 10,00%
KG 15000 8,00%
10000 6,00%
5000 4,00%
2,00%
0 333 441 515 528 735 768 1428 1478 1479 1553 1554 1555 1556 1562 1563 1564 1565 1566 1569 1570 1578 1579 1585 1653 1654 1681 1684 1692 1700 1716 0,00%
Total Kg Inspect 1087,8 25978 184 0 15145 15267 0 85008 64093 499,2 582,5 1895,4 4794 1740,8 487,9 2382 677,6 974 212,8 518,1 0 634,6 779,4 657,3 2523,1 0 175,5 1850,4 4856
Kg Reject srd 0 1171,8 0 0 624,78 273 1632 1953 3,2 30 26 221 43,2 22,1 32 4,4 16 0 11,55 0 0 29,7 0 18,4 0 6 62 464
% 0,00% 4,51% 0,00% 0,00% 4,13% 1,79% 0,00% 1,92% 3,05% 0,64% 5,15% 1,37% 4,61% 2,48% 4,53% 1,34% 0,65% 1,64% 0,00% 2,23% 0,00% 0,00% 3,81% 0 1% 0% 3% 3% 0% 10%
Hasil inspeksi quality menghasilkan reject SRD tertinggi pada BT 1716 sebesar 9,6%.
Percentage Reject Antar Group ( Per Product ) Oktober 2015
% 25,00%
24,00%
23,00% 333 441 515 528 735 768 1428 1478 1479 1553 1554 1555 1556 1562 1563 1564 1565 1566 1569 1570 1578 1579 1585 1653 1654 1681 1684 1692 1716
22,00% 0,00% 4,55% 0,00% 0,00% 3,38% 0,00% 5,15% 1,27% 5,08% 5,42% 0,00% 1,88% 0,00% 1,44% 0,00% 2,23% 0,00% 0,00% 3,81% 0,00% 0,57% 0,00% 3,4% 2% 4%
21,00% 0,00% 4,43% 0,00% 0,00% 7,89% 2,16% 8,05% 2,55% 2,69% 0,64% 0,00% 1,98% 4,36% 1,19% 4,53% 0,25% 0,66% 1,80% 0,00% 0,00% 0,00% 0,00% 0,00% 0,00% 0,87% 0,00% 4% 23%
20,00% 0
19,00% 1,44% 1,49% 1,39%
18,00%
17,00%
16,00%
15,00%
14,00%
13,00%
12,00%
11,00%
10,00%
9,00%
8,00%
7,00%
6,00%
5,00%
4,00%
3,00%
2,00%
1,00%
0,00%
Grup S
Grup T
16
PT. PRIKAST METAL INDONESIA Ref No : Q-05-PMI-X-2015
MONTHLY QUALITY REPORT Dep/Sec. : QUALITY
5.3 SAND RELATED DEFECT MACHINING Date : Oktober 2015
REPORT Sand Related Defect Machining Jan -
4 Des 2015
3,5
3
Procentage (%) 2,5
2
1,5
1
0,5
0 Jan Feb Mar April Mei Jun Jul Agu Sep Okt
SRD 3,39 2,66
Pada hasil machining bulan Oktober, reject SRD mengalami penurunan menjadi 2,66%
Percentage Inspect ( Kg ) vs ( Kg ) Reject SRD Machining Oktober 2015 6000
25,00%
20,00% 5000
15,00% 4000
10,00% 3000
5,00% 2000
1000
0,00% 333 441 515 528 735 768 1428 1478 1479 1553 1554 1555 1556 1562 1563 1564 1565 1566 1569 1570 1578 1579 1585 1653 1654 1681 1684 1692 1700 1716 0
Total Kg Inspect 743 3429 412 1856 4754 5098 4307 825 160 60 401 20
Kg Reject SRD 166,6 520,8 828 0 381,8 518 2080 1147 0 0 0 242,3 0 0 0 0 0 0 0 3,8 0 0 0 6,64 16,5 0 0
% 2,29%2,45%21,840,00%1,78%3,11%0,00%2,55%1,72%0,00%0,00%0,00%6,91%0,00%0,00%0,00%0,00%0,00%0,00%0,00%0,00%0,63%0,00%0,00%0,00%6,67%2,74%0,00%0,00%0,00%
Reject SRD hasil machining terbesar dihasilkan oleh BT 515 sebesar 21,84%.
17
PT. PRIKAST METAL INDONESIA Ref No : Q-05-PMI-X-2015
MONTHLY QUALITY REPORT Dep/Sec. : QUALITY
Date : Oktober 2015
5.4 Sand Properties & Komposisi Pasir DISA PMI Oktober 2015
900,0
800,0
700,0
600,0
500,0
400,0
300,0
200,0
T1a0r0,g0et (Pcs) JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
0% #####
Ac0tu,0al (Pcs) Comp. 0% #####
( % ) Permeabil Strength
(lbf/inch) Compact Moisture Mould AFS T.Clay Active Dead ##V#ol#. # 7L9O0I 1% Pasir Pasir baru Bentonite Sea Coal
ity (%) (%) Hardness Clay Clay lama
Matter
ReAmguas rk1s3/8E,4xplan29a,9tion: 40,4 3,3 0 66,2 11,5 9,4 800,0 9,0 4,4 1,5
1,5
PeOSenkptcapa1166i58a,,35n pro3322d,,10uktiv4400i,,t57as Co33r,,33e Hub Rear 66(02B,,89T. 14172,93 ) bul99a,,20n Sep2t,e3mber11,,258 015 m22,,63asih d8905i20b,,06awah98,,70target45,,,20 1,5
peNnovyebab utamanya adalah tingginya Prepare dan pemanasan core box.
Remarks/Explanation:
Pengujian hardness, total clay, dan dead clay tidak dilakukan dikarenakan trouble alat.
18
PT. PRIKAST METAL INDO
MONTHLY REPORT PRODUCTION
1 Laporan Product Engineering
1.1 Progress Production Development
NO CUSTOMER No NAME PRODUCT PART NO MATERIAL PICTURE 6.1 PROGRESS PROD
1 Harmoni ( Sentot ) Item HIZ415011 FCD 450
2015
OKT NOV DEC JAN FEB
I II III IV I II III IV I II III IV I II III IV I II III
1 Hub Whell (528)
2 Hub Fr Whell (1428) 8-97034-769-0 FCD 450
3 Shoulder ( PMI 017 ) 01-1ZG-W950001-0B-1 FCD 500
4 PMI_002 ( HUB Rr WHEEL ) 15024 FCD 500 A
5 PMI_003 ( BRAKE DRUM REAR ) 1501 FC 250
6 PMI_004 ( BRAKE DRUM FM/FN ) 15010 FC 250
7 PMI_005 ( BRAKE DRUM HINO ) 1503 FC 250
8 PMI_006 ( BRAKE DRUM ) 15014 FC 250
9 PMI_007 ( BRAKE DRUM FM/FN ) 1503 FC 250
2 KIRA CORP 1 Table NSD-13 R TB S-7-E FC 200
2 Table KID-420 TB KI-7-D FC 200
3 Bracket NSD-340 BR NS -4-E FC 150
4 Bracket KID-420 BR KI-4-G FC 150
3 IAMI 1 Brake Drum Pick Up
2 Brake Drum Wagon
3 Hand Brake Drum
4 Disc Brake
5 Bracket RWD Sub Spring ( BT 1701 )
6 Bracket Sub Spring Stopper ( BT 1700 )
7 Shackle ASM W BUSH ( BT 1655 )
8 Flywheel ASM
9 Bracket Torque BT ( 1497 )
10 Yoke Sleeve
11 Yoke Company
12 Yoke Flange
ONESIA Ref No : E-06-PMI-X-2015
N ENGINEERING Dep/Sec : Engineering/Maint
Date : October
DUCT DEVELOPMENT
2016 STATUS
MAR APR MEI JUN JUL PROGRESS LOI RE QUOTATION SCHADULE MAKING TRIAL SAMPLE MASS REMAKS
PROJECT DRAWING / PROGRES PATTERN CASTING PRO
Sudah ada di line
IV I II III IV I II III IV I II III IV I II III IV I II III IV MANAGEMENT SAMPLE produksi
Baru Buat Master
Pattern
Qty 200- 250 Pcs
Belum Ada info
Belum Ada info
Belum Ada info
Belum Ada info
Belum Ada info
Belum Ada info
Siap Pembuatan
Pattern tunggu
Drawing dari kira
Jepang
Menunggu Drawing /
Sample Casting
Menunggu Drawing /
Sample Casting
Menunggu Drawing /
Sample Casting
Menunggu Drawing /
Sample Casting
Menunggu Drawing /
Sample Casting
Menunggu Drawing /
Sample Casting
Menunggu Drawing /
Sample Casting
Menunggu Drawing /
Sample Casting
Menunggu Drawing /
Sample Casting
Sample sudah ada
Belum Ada Sample
Sample sudah ada
19
PT. PRIKAST METAL INDO
MONTHLY REPORT PRODUCTION
1 Laporan Product Engineering
1.1 Progress Production Development
NO CUSTOMER No NAME PRODUCT PART NO MATERIAL PICTURE PROGRESS PRODUC
Item
2015
13 Yoke OKT NOV DEC JAN FEB
I II III IV I II III IV I II III IV I II III IV I II III
14 Rear Axle Hub ( BT 1666 )
15 Hub Front Wheel ( BT 528 )
16 CAGE DIFF DRIVE PINION TAPER BEARING
17 CAP DIFFERENTIAL BEARING
18 Exhaust Adapter
19 Hub Front Axle
20 Disc Rotor ( BT 413 )
21 Bracket Spring ( 1701 )
4 KIRA CORP 1 KRT-10 1C-Z307-B BC2
S45C
2 Bracket KRDG-420 2B-2209-8B SCM415 Cr Mo
S45C
3 Cam KRDG-420 2B-2212-9D SCM415 Cr Mo
SKD
4 Bracket KRDG-340 3B-2209-8C S45C
S45C
5 Cam KRDG-340 3B-2214-10C FC200
S45C
6 Shaft KRDG-340 3B-2421-A S441-D
S45C
7 Shaft KRTG-420 2C-2403-E S45C
S45C
8 Shaft KRTG-420 2C-2422-C FC15
FC20
9 Cover KRTG-420 2C-2438-5A
10 Shaft KRDG-340 3B-2405-C
11 Holder KRT-340 3C-2321-A
12 KRDG-420P 4B-2201-8H
13 Shaft KRDG-420P 4B-2405-B
14 Shaft KRDG-420P 4B-2481-B
15 TSU-10 1C-1010
16 KRT-10 1C-2301-B
ONESIA Ref No : E-06-PMI-X-2015
N ENGINEERING Dep/Sec : Engineering/Maint
Date : October
CT DEVELOPMENT
2016 STATUS
MAR APR MEI JUN JUL PROGRESS LOI RE QUOTATION SCHADULE MAKING TRIAL SAMPLE MASS REMAKS
PROJECT DRAWING / PROGRES PATTERN CASTING PRO
IV I II III IV I II III IV I II III IV I II III IV I II III IV MANAGEMENT SAMPLE
Sample sudah ada
Tunggu Drawing
Tunggu Drawing
Tunggu Drawing
Tunggu Drawing
Tunggu Drawing
Tunggu Drawing
Proses Machining , Tunggu Drawing
Preparation Material next Tunggu Drawing
proses Machining
Proses Casting , Preparation
Pattern ,Molding ,Pouring,
Finishing,Finish dengan Machining.
Pengerjaan drawing
di Subcon dengan wkt
10 hari
20
PT. PRIKAST METAL INDO
MONTHLY REPORT PRODUCTION
1 Laporan Product Engineering
1.1 Progress Production Development
NO CUSTOMER No NAME PRODUCT PART NO MATERIAL PICTURE PROGRESS PRODUC
Item 1C-2302-B FC20
1C-2304-B 2015
1C-2305-A OKT NOV DEC JAN FEB
1C-2310
1C-2311 I II III IV I II III IV I II III IV I II III IV I II III
1C-2332-A
17 KRT-10 2C-2102-5G
2C-2202-D
18 KRT-10 2C-2250-2B FC15
2C-2359-3A
19 KRT-10 2C-2381-A FC15
2C-2382-A
20 KRT-10 2C-2411-D FC15
3C-2307-B
21 KRT-10 FC15
3C-2309-B
22 KRT-10 3C-2325-A FC20
3C-2360-A
23 Rack Sleeve KRTG-420 4B-2309-B FC200
4B-2310-A
24 Gear KRDG-420 4B-2325-A PBC-2
5C-2101-5F
25 Case KRTG-420 K1-15-5H FC15
K1-2360-1B
26 KRTG-420 KN-13-E FC15
27 Clutch KRTG-420 FC200
28 KRTG-420 FC15
29 Gear KRTG-420 PBC-2
30 Clutch KRT-340 FC200
FC200
31 Clutch KRT-340 FC200 Belum ada
drawingnya
32 Pulley KRT-340
33 KRT-340 FC15
34 KRT-340 FC15
35 KRDG-420P FC15
36 KRDG-420P FC15
37 KRDG-420P FC15
38 Rack-Sleeve FC200
39 Rack Sleeve FC200
40 KID-420 FC20
41 Rack Sleeve FC200
ONESIA Ref No : E-06-PMI-X-2015
N ENGINEERING Dep/Sec : Engineering/Maint
Date : October
CT DEVELOPMENT
2016 STATUS
MAR APR MEI JUN JUL PROGRESS LOI RE QUOTATION SCHADULE MAKING TRIAL SAMPLE MASS REMAKS
PROJECT DRAWING / PROGRES PATTERN CASTING PRO
IV I II III IV I II III IV I II III IV I II III IV I II III IV MANAGEMENT SAMPLE
In House team PE (
Tunggu Ipung masuk
tanggal 9 Nov '15 )
21
PT. PRIKAST METAL INDO
MONTHLY REPORT PRODUCTION
1 Laporan Product Engineering
1.1 Progress Production Development
NO CUSTOMER No NAME PRODUCT PART NO MATERIAL PICTURE PROGRESS PRODUC
Item KN-14-G S45C
KN-30-A 2015
NR-15-H OKT NOV DEC JAN FEB
NR-68-6B
R-7C I II III IV I II III IV I II III IV I II III IV I II III
42 Spindle PMI_008
PMI_013
43 Pulley FC20
44 Rack Sleeve FC200
45 Pulley FC200
46 Table FC200
1 Hub FC 250
2 Pully
5 PT FTR
FC 250
6 PAK WIKARTA 1 Ball Point ( Disc Brake ) SNCM 5
7 PT ABS (Perorangan ) 1 Drum , Rear Brake ( Vespa ) FC 250
8 Shakel FC 250
Pak Tulus
ONESIA Ref No : E-06-PMI-X-2015
N ENGINEERING Dep/Sec : Engineering/Maint
Date : October
CT DEVELOPMENT
2016 STATUS
MAR APR MEI JUN JUL PROGRESS LOI RE QUOTATION SCHADULE MAKING TRIAL SAMPLE MASS REMAKS
PROJECT DRAWING / PROGRES PATTERN CASTING PRO
IV I II III IV I II III IV I II III IV I II III IV I II III IV MANAGEMENT SAMPLE
Tunggu Progress Dari
Management
Tunggu Progress Dari
Management
Tunggu Progress Dari
Management
22
PT. PRIKAST METAL INDONESIA
MONTHLY REPORT PRODUCTION ENGINEER
1 Laporan Product Engineering
6.2 Schedule by Customer
( PT HARMONI ) SHOULDER
SHOULDER
ENGINEERING DEVELOPMENT : Project Leader : Production Engineering
Customer : SHOULDER
Part Name : 01-ZG-W950001-0B-1 Member : Eryan (Eng Proses), Harry (PE),Kosim ( Pattern ) Saidina Umar (Pattern), Irsan (QC), Mutiara (QA), Arie (PPIC), Tulus
Part No : 017 (Prod),
PMI. Number : FCD 500
Material : DISA .= Plan
Line Casting :
Line M/C 200-250 PCS .= Actual
Quantity
PIC START Date 29-Oct-15
NO ACTIVITY
MASTER SCHEDULE DETAIL FINISH WORKING WEIGHT PROGRESS PROGRESS PLAN / ACT Okt'15 2015
3/11/15 DAYS OF PART OF IV November'15
4/11/15 3 II III IV
5/11/15 1 PROJECT 30-31 I II
10/11/15 1 30
A FASE 1 : PREPARATION PE & Pattern 30/11/15 1 10% 0% 0.00% Plan 31-3 4-5
30/10/15 30% 0% 0.00% Actual 1 6
B FASE 2 : VALIDASI TOOLING PE & Pattern 3/11/15 03/11/15 1 40% 0% 0.00% Plan 4-5 6 Drawing 3D baru selesai
05/11/15 1 20% 0% 0.00% Actual core
C FASE 3 : VALIDASI PROSES Eng. casting 4/11/15 1 10% 9.00% Plan 4-5 9
8/11/15 05/11/15 3% 100% 3.00% Actual 5-6 9 Mundur 1 hari karena
D FASE 4 : MASS Eng. casting 06/11/15 1 2% 100% 2.00% Plan 5-6 9 material kurang , haru
PRODUCTION 06/11/15 1 5% 80% 4.00% Actual 5-6 sudah di hitung denga
06/11/15 1 30% 0.00% Plan dudukan core
1 7% 0% 0.00% Actual 6-7
A FASE 1 : PREPARATION 07/11/15 7% 0% 0.00% Plan 6-7
07/11/15 1 5% 0% 0.00% Actual 6-7
A1 Persiapan Material Pattern Pattern Design 29/10/15 07/11/15 1 11% 0% 0.00% Plan 6-7
07/11/15 1 40% 0.00% Actual 6-7
A2 Making Pattern Pattern Design 31/11/15 07/11/15 1 15% 0% 0.00% Plan
1 5% 0% 0.00% Actual 8
A3 Layot Pattern Pattern Design 04/11/15 09/11/15 5% 0% 0.00% Plan 8
09/11/15 1 5% 0% 0.00% Actual 8
B FASE 2 : VALIDASI 1 10% 0% 0.00% Plan
TOOLING 0 20% 0.00% Actual
14 7% 0% 0.00% Plan
B1 Casting Trial Eng. Casting 04/11/15 7% 0% 0.00% Actual
6% 0% 0.00% Plan
B2 Casting Trial Evaluation & Eng. Casting 05/11/15 100% Actual
Reporting 9% Plan
Actual
DETAIL SCHEDULE B3 Initial Sample Eng. Casting 05/11/15 Plan
Actual
B4 Sample Approval ( Validasi PM I-CUS 05/11/15 Plan
Tooling ) Actual
Plan
C FASE 3 : VALIDASI PROSES Actual
Plan
C1 Control Plan Process Eng. Casting 06/11/15 Actual
Validation Plan
Actual
C2 Update Inspection Standard Pattern Design 06/11/15 Plan
Actual
C3 Update WI/SOP Eng. Casting 06/11/15 Plan
Actual
C4 Packaging Standard Eng. Casting 06/11/15 Plan
Actual
C5 Production Trial Eng. Casting 06/11/15 Plan
Actual
D FASE 4 : MASS Plan
PRODUCTION Actual
D1 Engineering Change Issue Eng. Casting 08/11/15
(ECI) 08/11/15
D2 Surat Keterangan Laik Quality
Produksi (SKLP)
D3 Mass Production Production 09/11/15
TOTAL PROGRESS
REM
RING Ref No : E-06-PMI-X-2015
( PMI_017 ) Dep/Sec : Engineering/Maint
Date : October
SKETCH/FOTO
PREPARED CHECKED APPROVED
2016
January February March Mei
III IV I II III IV I II III IV I II III IV I II III IV
a
usnya
an
Selesai Pengerjaan Pattern
+ Core Box
MARKS
23
PT. PRIKAST METAL INDONESIA
MONTHLY REPORT PRODUCTION ENGINEER
( PT FTR ) Hub 12-08490
MASTER SCHEDULE &
Hub 12
ENGINEERING DEVELOPMENT : PT FTR Project Leader : Production Engineering
Customer : Hub
Part Name : 12-08490 Member : Eryan (Eng Proses), Harry (PE),Kosim ( Pattern ) Saidina Umar (Pattern), Irsan (QC), Mutiara (QA), Arie (PPIC), Tulus
Part No : 015 (Prod),
PMI. Number : FC 25
Material : DISA .= Plan
Line Casting :
Line M/C .= Actual
Quantity PIC
Date 12-Nov-15
NO ACTIVITY
DETAIL START FINISH WORKING WEIGHT PROGRESS PROGRESS PLAN / ACT November 2015 Dece
08/12/15 DAYS OF PART OF II III II
16/12/15 15 10% IV I
26/12/15 8 30% PROJECT I 23 08 17-26
30/12/15 10 40%
A FASE 1 : PREPARATION Pattern 23/11/15 5 20% 0% 0.00% Plan 09-16
25/11/15 10% 0% 0.00% Actual
MASTER B FASE 2 : VALIDASI TOOLING PE & Pattern 09/12/15 30/11/15 3 3% 0% 0.00% Plan
SCHEDULE 02/12/15 10 2% 0% 0.00% Actual
C FASE 3 : VALIDASI PROSES Eng. casting 17/12/15 2 5% 3.00% Plan
28/12/15 26/11/15 30% 100% 3.00% Actual
D FASE 4 : MASS Eng. casting 28/11/15 2 7% 0% 0.00% Plan
PRODUCTION 29/11/15 2 7% 0% 0.00% Actual
01/12/15 2 5% 0.00% Plan
A FASE 1 : PREPARATION 2 11% 0% 0.00% Actual
05/12/15 40% 0% 0.00% Plan
A1 Persiapan Material Pattern Pattern Design 23/11/15 08/12/15 2 15% 0% 0.00% Actual 23-25
09/12/15 2 5% 0% 0.00% Plan 26
A2 Making Pattern Pattern Design 28/11/15 11/12/15 2 5% 0.00% Actual 6
15/12/15 2 5% 0% 0.00% Plan 7-8
A3 Layot Pattern Pattern Design 1/12/15 2 10% 0% 0.00% Actual
16/12/15 20% 0% 0.00% Plan
B FASE 2 : VALIDASI 18/12/15 2 7% 0% 0.00% Actual
TOOLING 2 7% 0% 0.00% Plan
1 6% 0.00% Actual
B1 Casting Trial Eng. Casting 25/11/15 38 100% 0% 0.00% Plan 09-10
0% 0.00% Actual 11-12
B2 Casting Trial Evaluation & Eng. Casting 27/11/15 0% 0.00% Plan 13-14
Reporting Actual 15-16
3% Plan
DETAIL SCHEDULE B3 Initial Sample Eng. Casting 28/11/15 Actual
Plan
B4 Sample Approval ( Validasi PMI-PT FTR 30/11/15 Actual
Tooling ) Plan
Actual
C FASE 3 : VALIDASI PROSES Plan
Actual
C1 Control Plan Process Eng. Casting 04/12/15 Plan 17-18
Validation Actual 19-20
Plan 21-22
C2 Update Inspection Standard Pattern Design 07/12/15 Actual 23-24
Plan 25-26
C3 Update WI/SOP Eng. Casting 08/12/15 Actual
Plan
C4 Packaging Standard Eng. Casting 10/12/15 Actual
Plan
C5 Production Trial Eng. Casting 14/12/15 Actual
Plan
D FASE 4 : MASS Actual
PRODUCTION Plan
Actual
D1 Engineering Change Issue Eng. Casting 15/12/15
(ECI) 17/12/15
D2 Surat Keterangan Laik Quality
Produksi (SKLP)
D3 Mass Production Production 19/12/15
TOTAL PROGRESS
REM
RING Ref No : E-06-PMI-X-2015
Dep/Sec : Engineering/Maint
& PROGRESS REPORT Date : October
2-08490
SKETCH/FOTO
PREPARED CHECKED APPROVED
2016
mber January February March Mei
III IV I II III IV I II III IV I II III IV I II III IV
28 30
28 30
29
MARKS
24
PT. PRIKAST METAL INDONESIA
MONTHLY REPORT PRODUCTION ENGINEER
( PT FTR ) Pully 13-10812
MASTER SCHEDULE &
Pully 13
ENGINEERING DEVELOPMENT : PT FTR Project Leader : Production Engineering
Customer : Pully
Part Name : 13-10812 Member : Eryan (Eng Proses), Harry (PE),Kosim ( Pattern ) Saidina Umar (Pattern), Irsan (QC), Mutiara (QA), Arie (PPIC), Tulus
Part No : 016 (Prod),
PMI. Number : FC 25
Material : DISA .= Plan
Line Casting :
Line M/C .= Actual
Quantity PIC
Date 12-Nov-15
NO ACTIVITY
DETAIL START FINISH WORKING WEIGHT PROGRESS PROGRESS PLAN / ACT November 2015 Dece
28/11/15 DAYS OF PART OF II III II
05/12/15 16 10% IV I 15
16/12/15 8 30% PROJECT I 30
20/12/15 10 40% 16
A FASE 1 : PREPARATION Pattern 09/11/15 5 20% 0% 0.00% Plan
11/11/15 10% 0% 0.00% Actual
MASTER B FASE 2 : VALIDASI TOOLING PE & Pattern 30/11/15 26/11/15 3 3% 0% 0.00% Plan
SCHEDULE 28/11/15 10 2% 0% 0.00% Actual
C FASE 3 : VALIDASI PROSES Eng. casting 07/12/15 2 5% 3.00% Plan
18/12/15 01/12/15 30% 100% 3.00% Actual
D FASE 4 : MASS Eng. casting 03/12/15 2 7% 0% 0.00% Plan
PRODUCTION 04/12/15 2 7% 0% 0.00% Actual
06/12/15 2 5% 0.00% Plan
A FASE 1 : PREPARATION 2 11% 0% 0.00% Actual
10/12/15 40% 0% 0.00% Plan
A1 Persiapan material pattern Pattern Design 09/11/15 12/12/15 2 15% 0% 0.00% Actual 30-1
14/12/15 2 5% 0% 0.00% Plan 3 13
A2 Making Pattern Pattern Design 14/11/15 16/12/15 2 5% 0.00% Actual 14-15
18/12/15 2 5% 0% 0.00% Plan
A3 Layot Pattern Pattern Design 27/11/15 2 10% 0% 0.00% Actual 16-17
19/12/15 20% 0% 0.00% Plan 17-18
B FASE 2 : VALIDASI 21/12/15 2 7% 0% 0.00% Actual 19-20
TOOLING 2 7% 0% 0.00% Plan
1 6% 0.00% Actual
B1 Casting Trial Eng. Casting 30/12/15 38 100% 0% 0.00% Plan
0% 0.00% Actual
B2 Casting Trial Evaluation & Eng. Casting 02/12/15 0% 0.00% Plan
Reporting Actual
3% Plan
DETAIL SCHEDULE B3 Initial Sample Eng. Casting 03/12/15 Actual
Plan
B4 Sample Approval ( Validasi PMI-PT FTR 05/12/15 Actual
Tooling ) Plan
Actual
C FASE 3 : VALIDASI PROSES Plan
Actual
C1 Control Plan Process Eng. Casting 09/12/15 Plan
Validation Actual
Plan
C2 Update Inspection Standard Pattern Design 11/12/15 Actual
Plan
C3 Update WI/SOP Eng. Casting 13/12/15 Actual
Plan
C4 Packaging Standard Eng. Casting 15/12/15 Actual
Plan
C5 Production Trial Eng. Casting 17/12/15 Actual
Plan
D FASE 4 : MASS Actual
PRODUCTION Plan
Actual
D1 Engineering Change Issue Eng. Casting 18/12/15
(ECI) 20/12/15
D2 Surat Keterangan Laik Quality
Produksi (SKLP)
D3 Mass Production Production 22/12/15
TOTAL PROGRESS
REM
RING Ref No : E-06-PMI-X-2015
Dep/Sec : Engineering/Maint
& PROGRESS REPORT Date : October
3-10812
SKETCH/FOTO
PREPARED CHECKED APPROVED
2016
mber January February March Mei
III IV I II III IV I II III IV I II III IV I II III IV
23 4
24
22-23
24-27
28-29 31
30 1-2
3-4
4
4
4
MARKS
25
PT. PRIKAST METAL INDONESIA
MONTHLY REPORT PRODUCTION ENGINEER
( PT KIRA ) Table NSD -13 R
MASTER SCHEDULE &
TABLE NSD-13
ENGINEERING DEVELOPMENT : KIRA Project Leader : Production Engineering
Customer : TABLE NSD-13 R
Part Name : TB S-7-E Member : Eryan (Eng Proses), Harry (PE),Kosim ( Pattern ) Saidina Umar (Pattern), Irsan (QC), Mutiara (QA), Arie (PPIC), Tulus
Part No : 009 (Prod),
PMI. Number : FC 20
Material : DISA .= Plan
Line Casting :
Line M/C : .= Actual
Quantity
PIC START Date 20-Nov-15
NO ACTIVITY
DETAIL FINISH WORKING WEIGHT PROGRESS PROGRESS PLAN / ACT November'15 Desember'15
DAYS OF PART OF II III IV I II
25-Nov-15 6 10% 25
01-Dec-15 6 30% PROJECT I 20
08-Dec-15 7 40% 26 01
A FASE 1 : PREPARATION PE & Pattern 20-Nov-15 10-Dec-15 2 20% Plan 20
10% 0% 0.00% 20 02 08
MASTER 20-Nov-15 1 3%
SCHEDULE 24-Nov-15 4 2% Actual 09-10
25-Nov-15 1 5%
B FASE 2 : VALIDASI TOOLING PE & Pattern 26-Nov-15 01-Dec-15 30% Plan 25
26-Nov-15 1 7% 0% 0.00%
28-Nov-15 2 7%
30-Nov-15 2 5% Actual
01-Dec-15 1 11%
C FASE 3 : VALIDASI PROSES Eng. casting 02-Dec-15 08-Dec-15 40% Plan
03-Dec-15 2 15% 0% 0.00%
04-Dec-15 1 5%
05-Dec-15 1 5% Actual
06-Dec-15 1 5%
D FASE 4 : MASS Eng. casting 09-Dec-15 08-Dec-15 2 10% Plan
PRODUCTION 10-Dec-15 20% 0% 0.00%
09-Dec-15 1 7%
10-Dec-15 1 7% Actual
10-Dec-15 0 6%
A FASE 1 : PREPARATION 21 100% 0.00% Plan
Actual
A1 Persiapan Material Pattern Pattern Design 20-Nov-15 Plan
0% 0.00%
Actual
A2 Making Pattern Pattern Design 21-Nov-15 Plan 21-24
0% 0.00% 25
26
Actual 26
A3 Layot Pattern Pattern Design 25-Nov-15 Plan 27-28
0% 0.00% 29-30
Actual
B FASE 2 : VALIDASI 26-Nov-15 0.00% Plan 01
TOOLING Actual
01
B1 Casting Trial Eng. Casting 26-Nov-15 Plan 02
0% 0.00% 02-03
04
Actual 05
B2 Casting Trial Evaluation & Eng. Casting 27-Nov-15 Plan
Reporting 0% 0.00%
Actual
B3 Initial Sample Eng. Casting 29-Nov-15 Plan
0% 0.00%
Actual
B4 Sample Approval ( Validasi PM I-KIRA 01-Dec-15 Plan
Tooling ) 0% 0.00%
Actual
C FASE 3 : VALIDASI PROSES 02-Dec-15 0.00% Plan 08
Actual
06
C1 Control Plan Process Eng. Casting 02-Dec-15 Plan 07-08
Validation 0% 0.00% 09-10
Actual 09
10
C2 Update Inspection Standard Pattern Design 04-Dec-15 Plan 10
0% 0.00%
Actual
C3 Update WI/SOP Eng. Casting 05-Dec-15 Plan
0% 0.00%
Actual
C4 Packaging Standard Eng. Casting 06-Dec-15 Plan
0% 0.00%
Actual
C5 Production Trial Eng. Casting 07-Dec-15 Plan
0% 0.00%
Actual
D FASE 4 : MASS 09-Dec-15 0.00% Plan
PRODUCTION 09-Dec-15 Actual
10-Dec-15
D1 Engineering Change Issue Eng. Casting Plan
(ECI) 0% 0.00%
Actual
D2 Surat Keterangan Laik Quality Plan
Produksi (SKLP) 0% 0.00%
Actual
D3 Mass Production Production 10-Dec-15 Plan
0% 0.00%
TOTAL PROGRESS
Actual
0%
REM
RING Ref No : E-06-PMI-X-2015
Dep/Sec : Engineering/Maint
& PROGRESS REPORT Date : October
3 R( PMI_009 )
SKETCH/FOTO
PREPARED CHECKED APPROVED
2016
5 January February March Mei
III IV I II III IV I II III IV I II III IV I II III IV
MARKS
26
PT. PRIKAST METAL INDONESIA
MONTHLY REPORT PRODUCTION ENGINEER
( PT KIRA ) Table KID-420
MASTER SCHEDULE &
TABLE KID-42
ENGINEERING DEVELOPMENT : KIRA Project Leader : Production Engineering
Customer : TABLE KID-420
Part Name TB KI-7-D Member : Eryan (Eng Proses), Harry (PE),Kosim ( Pattern ) Saidina Umar (Pattern), Irsan (QC), Mutiara (QA), Arie (PPIC), Tulus
Part No : 010 (Prod),
PMI. Number : FC 20
Material : DISA .= Plan
Line Casting :
Line M/C : .= Actual
Quantity
PIC START Date 30-Nov-15
NO ACTIVITY
DETAIL FINISH WORKING WEIGHT PROGRESS PROGRESS PLAN / ACT Desember'15 Janua
DAYS OF PART OF II III II
10%
30% PROJECT I IV I REM
40% 30-05 19-20
A FASE 1 : PREPARATION PE & Pattern 30-Nov-15 05-Dec-15 6 20% Plan
10% 0% 0.00% 30-05 19-20
MASTER 3% 30 19
SCHEDULE 2% Actual 20
5% 01-04 20
B FASE 2 : VALIDASI TOOLING PE & Pattern 06-Dec-15 11-Dec-15 6 30% Plan 05 06-11
7% 0% 0.00%
7%
5% Actual
11%
C FASE 3 : VALIDASI PROSES Eng. casting 12-Dec-15 18-Dec-15 7 40% Plan Dec-18
15% 0% 0.00%
5%
5% Actual
5%
D FASE 4 : MASS Eng. casting 19-Dec-00 20-Dec-16 2 10% Plan
PRODUCTION 20% 0% 0.00%
7%
7% Actual
6%
A FASE 1 : PREPARATION 100% 0.00% Plan
Actual
A1 Persiapan Material Pattern Pattern Design 30-Nov-15 30-Dec-15 1 Plan
04-Dec-15 4 0% 0.00%
05-Dec-15 1
11-Dec-15 Actual
06-Dec-15 1
A2 Making Pattern Pattern Design 01-Dec-15 08-Dec-15 2 Plan
10-Dec-15 2 0% 0.00%
11-Dec-15 1
18-Dec-15 Actual
13-Dec-15 2
A3 Layot Pattern Pattern Design 05-Dec-15 14-Dec-15 1 Plan
15-Dec-15 1 0% 0.00%
16-Dec-15 1
18-Dec-15 2 Actual
20-Dec-16
B FASE 2 : VALIDASI 06-Dec-15 19-Dec-00 1 0.00% Plan 06-11
TOOLING 20-Dec-16 1 Actual 06
20-Dec-16 0
B1 Casting Trial Eng. Casting 06-Dec-15 21 Plan 07-08
0% 0.00% 09-10
Actual 11
B2 Casting Trial Evaluation & Eng. Casting 07-Dec-15 Plan
Reporting 0% 0.00%
Actual
B3 Initial Sample Eng. Casting 09-Dec-15 Plan
0% 0.00%
Actual
B4 Sample Approval ( Validasi PM I-KIRA 11-Dec-15 Plan
Tooling ) 0% 0.00%
Actual
C FASE 3 : VALIDASI PROSES 12-Dec-15 0.00% Plan 12-18
Actual 12-13
C1 Control Plan Process Eng. Casting 12-Dec-15 Plan 14
Validation 0% 0.00% 15
16
Actual 17-18
C2 Update Inspection Standard Pattern Design 14-Dec-15 Plan
0% 0.00%
Actual
C3 Update WI/SOP Eng. Casting 15-Dec-15 Plan
0% 0.00%
Actual
C4 Packaging Standard Eng. Casting 16-Dec-15 Plan
0% 0.00%
Actual
C5 Production Trial Eng. Casting 17-Dec-15 Plan
0% 0.00%
Actual
D FASE 4 : MASS 19-Dec-00 0.00% Plan
PRODUCTION 19-Dec-00 Actual
20-Dec-16
D1 Engineering Change Issue Eng. Casting Plan
(ECI) 0% 0.00%
Actual
D2 Surat Keterangan Laik Quality Plan
Produksi (SKLP) 0% 0.00%
Actual
D3 Mass Production Production 20-Dec-15 Plan
0% 0.00%
TOTAL PROGRESS
Actual
0%
RING Ref No : E-06-PMI-X-2015
Dep/Sec : Engineering/Maint
& PROGRESS REPORT Date : October
20 ( PMI_010 )
SKETCH/FOTO
PREPARED CHECKED APPROVED
2016
ary'16 February'16 March'16 April'16 Mei'16
III IV I II III IV I II III IV I II III IV I II III IV
MARKS
27
PT. PRIKAST METAL INDONESIA
MONTHLY REPORT PRODUCTION ENGINEER
( PT KIRA ) Bracket NSD-340
MASTER SCHEDULE &
BRACKET NSD-
ENGINEERING DEVELOPMENT : KIRA Project Leader : Production Engineering
Customer : BRACKET NSD-340
Part Name : BR NS-4-E Member : Eryan (Eng Proses), Harry (PE),Kosim ( Pattern ) Saidina Umar (Pattern), Irsan (QC), Mutiara (QA), Arie (PPIC), Tulus
Part No : 011 (Prod),
PMI. Number : FC 15
Material : DISA .= Plan
Line Casting :
Line M/C : .= Actual
Quantity
PIC START Date 09-Dec-15
NO ACTIVITY
DETAIL FINISH WORKING WEIGHT PROGRESS PROGRESS PLAN / ACT Desember'15 Janu
14-Dec-15 DAYS OF PART OF I II III II
20-Dec-15 6 10%
27-Dec-15 6 30% PROJECT 09 14 IV I REM
29-Dec-15 7 40% 15 20 27
A FASE 1 : PREPARATION PE & Pattern 09-Dec-15 2 20% Plan 21 28-29
09-Dec-15 10% 0% 0.00% 09 14
MASTER 14-Dec-15 1 3% 09 20 27
SCHEDULE 15-Dec-15 4 2% Actual 10 14
1 5% 19 26-27
B FASE 2 : VALIDASI TOOLING PE & Pattern 15-Dec-15 15-Dec-15 30% Plan 15 20 28-29
17-Dec-15 1 7% 0% 0.00% 15 21
19-Dec-15 2 7% 15 21-22 28
20-Dec-15 2 5% Actual 16-17 23 29
1 11% 18 24 29
C FASE 3 : VALIDASI PROSES Eng. casting 21-Dec-15 22-Dec-15 40% Plan 25
23-Dec-15 2 15% 0% 0.00%
24-Dec-15 1 5%
25-Dec-15 1 5% Actual
27-Dec-15 1 5%
D FASE 4 : MASS Eng. casting 28-Dec-15 2 10% Plan
PRODUCTION 28-Dec-15 20% 0% 0.00%
29-Dec-15 1 7%
29-Dec-15 1 7% Actual
0 6%
A FASE 1 : PREPARATION 21 100% 0.00% Plan
Actual
A1 Persiapan Material Pattern Pattern Design 09-Dec-15 Plan
0% 0.00%
Actual
A2 Making Pattern Pattern Design 10-Dec-15 Plan
0% 0.00%
Actual
A3 Layot Pattern Pattern Design 15-Dec-15 Plan
0% 0.00%
Actual
B FASE 2 : VALIDASI 0.00% Plan
TOOLING Actual
B1 Casting Trial Eng. Casting 15-Dec-15 Plan
0% 0.00%
Actual
B2 Casting Trial Evaluation & Eng. Casting 16-Dec-15 Plan
Reporting 0% 0.00%
Actual
B3 Initial Sample Eng. Casting 18-Dec-15 Plan
0% 0.00%
Actual
B4 Sample Approval ( Validasi PM I-KIRA 20-Dec-15 Plan
Tooling ) 0% 0.00%
Actual
C FASE 3 : VALIDASI PROSES 0.00% Plan
Actual
C1 Control Plan Process Eng. Casting 21-Dec-15 Plan
Validation 0% 0.00%
Actual
C2 Update Inspection Standard Pattern Design 23-Dec-15 Plan
0% 0.00%
Actual
C3 Update WI/SOP Eng. Casting 24-Dec-15 Plan
0% 0.00%
Actual
C4 Packaging Standard Eng. Casting 25-Dec-15 Plan
0% 0.00%
Actual
C5 Production Trial Eng. Casting 26-Dec-15 Plan
0% 0.00%
Actual
D FASE 4 : MASS 0.00% Plan
PRODUCTION Actual
D1 Engineering Change Issue Eng. Casting 28-Dec-15 Plan
(ECI) 29-Dec-15 0% 0.00%
Actual
D2 Surat Keterangan Laik Quality Plan
Produksi (SKLP) 0% 0.00%
Actual
D3 Mass Production Production 29-Dec-15 Plan
0% 0.00%
TOTAL PROGRESS
Actual
0%
RING Ref No : E-06-PMI-X-2015
Dep/Sec : Engineering/Maint
& PROGRESS REPORT Date : October
340 ( PMI_011 )
SKETCH/FOTO
PREPARED CHECKED APPROVED
2016
uary February March April Mei
III IV I II III IV I II III IV I II III IV I II III IV
MARKS
28
PT. PRIKAST METAL INDONESIA
MONTHLY REPORT PRODUCTION ENGINEER
( PT KIRA ) Bracket KID-420
MASTER SCHEDULE &
BRACKET KID-4
ENGINEERING DEVELOPMENT : KIRA Project Leader : Production Engineering
Customer : BRACKET KID-420
Part Name : BR KI-4-G Member : Eryan (Eng Proses), Harry (PE),Kosim ( Pattern ) Saidina Umar (Pattern), Irsan (QC), Mutiara (QA), Arie (PPIC), Tulus
Part No : 012 (Prod),
PMI. Number : FC 150
Material : DISA .= Plan
Line Casting :
Line M/C : .= Actual
Quantity
PIC START Date 28-Dec-15
NO ACTIVITY
DETAIL FINISH WORKING WEIGHT PROGRESS PROGRESS PLAN / ACT Desember'15 Janu
23-Dec-15 DAYS OF PART OF I II III II
28-Dec-15 6 10%
05-Dec-15 6 30% PROJECT 18 IV I
07-Dec-15 7 40% 23
A FASE 1 : PREPARATION PE & Pattern 18-Dec-15 2 20% Plan 18
18-Dec-15 10% 0% 0.00% 18
MASTER 22-Dec-15 1 3%
SCHEDULE 23-Dec-15 4 2% Actual
1 5%
B FASE 2 : VALIDASI TOOLING PE & Pattern 24-Dec-15 24-Dec-15 30% Plan 24 28
26-Dec-15 1 7% 0% 0.00%
28-Dec-15 2 7%
29-Dec-15 2 5% Actual
1 11%
C FASE 3 : VALIDASI PROSES Eng. casting 30-Dec-15 31-Dec-15 40% Plan 30 05
01-Jan-16 2 15% 0% 0.00%
02-Jan-16 1 5%
03-Jan-16 1 5% Actual
05-Jan-16 1 5%
D FASE 4 : MASS Eng. casting 06-Dec-15 2 10% Plan 06-07
PRODUCTION 06-Dec-15 20% 0% 0.00%
07-Jan-16 1 7%
07-Jan-16 1 7% Actual
0 6%
A FASE 1 : PREPARATION 21 100% 0.00% Plan 23
Actual
A1 Persiapan Material Pattern Pattern Design 18-Dec-15 Plan
0% 0.00%
Actual
A2 Making Pattern Pattern Design 19-Dec-15 Plan 19-22
0% 0.00% 23
24
Actual 24
25
A3 Layot Pattern Pattern Design 23-Dec-15 Plan
0% 0.00%
Actual
B FASE 2 : VALIDASI 0.00% Plan 28
TOOLING Actual
26
B1 Casting Trial Eng. Casting 24-Dec-15 Plan 27-28
0% 0.00%
29
Actual 30
30-31
B2 Casting Trial Evaluation & Eng. Casting 25-Dec-15 Plan 01
Reporting 0% 0.00%
Actual
B3 Initial Sample Eng. Casting 27-Dec-15 Plan
0% 0.00%
Actual
B4 Sample Approval ( Validasi PM I-KIRA 29-Dec-15 Plan
Tooling ) 0% 0.00%
Actual
C FASE 3 : VALIDASI PROSES 0.00% Plan 05
Actual
02
C1 Control Plan Process Eng. Casting 30-Dec-15 Plan 03
Validation 0% 0.00% 04-05
06-07
Actual 06
07
C2 Update Inspection Standard Pattern Design 01-Jan-16 Plan 07
0% 0.00%
Actual
C3 Update WI/SOP Eng. Casting 02-Jan-16 Plan
0% 0.00%
Actual
C4 Packaging Standard Eng. Casting 03-Jan-16 Plan
0% 0.00%
Actual
C5 Production Trial Eng. Casting 04-Jan-16 Plan
0% 0.00%
Actual
D FASE 4 : MASS 0.00% Plan
PRODUCTION Actual
D1 Engineering Change Issue Eng. Casting 06-Dec-15 Plan
(ECI) 07-Jan-16 0% 0.00%
Actual
D2 Surat Keterangan Laik Quality Plan
Produksi (SKLP) 0% 0.00%
Actual
D3 Mass Production Production 07-Jan-16 Plan
0% 0.00%
TOTAL PROGRESS
Actual
0%
REM
RING Ref No : E-06-PMI-X-2015
Dep/Sec : Engineering/Maint
& PROGRESS REPORT Date : October
420 ( PMI_012 )
SKETCH/FOTO
PREPARED CHECKED APPROVED
2016
uary February March April Mei
III IV I II III IV I II III IV I II III IV I II III IV
MARKS
29
PT. PRIKAST METAL INDONESIA Rev No : E-07-PMI-X-2015
Dept : Engineering Processs
LAPORAN ENGINEERING PROCESS Date : OctoObecrtober
1. Tujuan
- Mengetahui kebutuhan material charging aktual vs standard
- Menghitung biaya operasional (melting) sesuai pemakaian aktual vs standard racikan
- Mengetahui strategi charging aktual dengan perbandingan productivity dan lose time produksi
- Standarisasi proses charging untuk acuan material requirement planning
2. Data
2.1 Data Furnace PT PMI
Furnace = F01 Furnace = F02 Furnace = F03
Kapasitas = 2 ton Kapasitas = 5 ton Kapasitas = 5 ton
Merk = Toshiba Merk = Toshiba Merk = BBC
Frequensi = Low Freq Frequensi = Low Freq Frequensi = Low Freq
Power max = 700 Kwh Power max = 1150 Kwh Power max = 1100 Kwh
7.1 EVALUASI PEMAKAIAN MATERIAL CHARGING OCTOBER
Data pemakaian material vs standard racikan
Data Standard Racikan Material
A. Material FCD (kapasitas 5 ton)
Kapasitas Furnace : 4800 Kg
No Material Charging Berat Persentase Komposisi Material Charging (%) Customer
(Kg) Berat
C Si Mn S P Cr Cu Al Sn Ni PT Metloy
PT Metloy
1 Scrap Auto 500 10% 0,11% 0,022% 0,15% 0,012% 0,017% 0,023% 0,013% 0,020% 0,00010% 0,0040%
2 Scrap high Mn 0% 0,14% 0,036% 0,48% 0,0063% 0,011% 0,070% 0,006% 0,019% 0,00% 0,032% PT Metloy
3 Non Auto 0 0% 0,00% 0,000% 0,00% 0,000% 0,000% 0,00% 0,00% 0,000% 0,000% PT Adhikarya
4 Kawat 600 13% 0,43% 0,06% 0,18% 0,004% 0,009% 0,015% 0,23% 0,020% 0,000%
0% 0,00010% 0,00060% PMI
5 Gram 0 35% 3,50% 2,25% 0,65% 0,03% 0,03% 0,25% 0,25% 0,010% PMI
6 Return FCD 1700 0% 3,80% 2,90% 0,25% 0,010% 0,030% 0,09% 0,20% 0,005% 0,000% 0,000% PMI
42% 0,009% 0,005%
7 Hill (FC) 0 3,59% 1,90% 0,64% 0,009% 0,018% 0,065% 0,18% 0,000%
Hill (FCD) 2000 100% 4,11% 2,06% 0,27% 0,009% 0,017% 0,012% 0,21% 0,000% 0,009% 0,005%
4800 0,010% 0,006%
Berat Aktual (Kg)
Komposisi Material Charging - Furnace(Kg)
C Si Mn S P Cr Cu Al Sn Ni
0,55 0,11
0,75 0,06 0,085 0,115 0,065 0,1 0,0005 0,02
0 0 0 0 0 0
0 0 0 0 00 0 0 0 0
2,58 0,36
0 0 0 0 00 1,38 0,12 0,0006 0,0036
64,6 49,3 0 0 0 0
0 0 1,08 0,024 0,054 0,09 3,4
82,2 41,2 0 0,085 0,153 0,085
147,35 90,61 0 0 00 4,2 0 0 0
0 0,2
Hill FCD Komposisi 4,25 0,17 0,51 1,53 7,665 0,12
Material Aktual 0,185 0,3535 0,225 Hill FCD
Unsur 0 0 00
3,070%
C 1,888% 5,4 0,18 0,34 0,24
Si 0,217%
Mn 0,009% 10,4 0,41 0,935 1,885
S 0,019%
P 0,039% Komposisi Hill FCD Berat % Customer
Cr 0,160% Target
Cu 0,004% Material (Kg) Furnace
Al 0,007% 3,90% No Additive
Sn 0,005% 2,00% 57 1,19% PT Metloy
Ni 0,25% 1 Arang Batok 8 0,16% PT Metloy
0,015% 2 Carburizer
0,025% 3 FeSi 3 0,06% PT Metloy
0,08% 4 FeMn 0,43 0,01% PT Metloy
0,20% 5 FeCr 2,76 0,06% PT Metloy
0,01% 6 Cu 0,00%
0,01% 7 SiC
0,01%
Cost Material Charging
Material Harga Mat Cost Prod
5100
Scrap Low 2550000
Scrap High 4200 0
3900
Kawat 6500 2520000
Gram 17000 0
Carburizer 14700
FeSi 19000 370036
FeMn 77000 130900
FeCr 39200
FeCu
Total 8121
212850
5831107
30
PT. PRIKAST METAL INDONESIA Rev No : E-07-PMI-X-2015
LAPORAN ENGINEERING PROCESS Dept : Engineering Process
DaOtect:oOctoberber
B. Material FCD (kapasitas 2 ton)
Kapasitas Furnace : 1800 Kg
No Material Charging Berat Persentase Komposisi Material Charging (%) Customer
(Kg)
Berat C Si Mn S P Cr Cu Al Sn Ni PT Metloy
PT Metloy
1 Scrap Auto 300 17% 0,11% 0,022% 0,15% 0,012% 0,017% 0,023% 0,013% 0,020% 0,00010% 0,0040%
2 Scrap high Mn 0% 0,14% 0,036% 0,48% 0,0063% 0,019% 0,00% 0,032% PT Metloy
3 Non Auto 0 0% 0,00% 0,000% 0,00% 0,000% 0,011% 0,070% 0,006% 0,000% 0,000% PT Adhikarya
4 Kawat 400 22% 0,43% 0,06% 0,18% 0,004% 0,020% 0,000%
0% 0,000% 0,00% 0,00% 0,00010% 0,00060% PMI
5 Gram 0 33% 3,50% 2,25% 0,65% 0,03% 0,009% 0,015% 0,23% 0,010% 0,000% PMI
6 Return FCD 600 0% 3,80% 2,90% 0,25% 0,010% 0,005% 0,000% 0,005% PMI
28% 0,03% 0,25% 0,25% 0,009% 0,005%
7 Hill (FC) 0 100% 3,59% 1,90% 0,64% 0,009% 0,030% 0,09% 0,20% 0,000% 0,009% 0,006%
8 Hill (FCD) 500 4,11% 2,06% 0,27% 0,009% 0,000% 0,010%
0,018% 0,065% 0,18%
0,017% 0,012% 0,21%
1800 Berat Aktual (Kg)
Komposisi Material Charging - Furnace(Kg)
C Si Mn S P Cr Cu Al Sn Ni
0,33 0,066
0,45 0,036 0,051 0,069 0,039 0,06 0,0003 0,012
0 0 0 0 0 0
0 0 0 0 00 0 0 0 0
1,72 0,24
0 0 0 0 00 0,92 0,08 0,0004 0,0024
22,8 17,4 0 0 0 0
0 0 0,72 0,016 0,036 0,06 1,2
20,55 10,3 0 0,03 0,054 0,03
24,85 17,706 0 0 00 0 0 0
43,68 27,766 1,05 0
1,5 0,06 0,18 0,54 2,159 0,05 0,03
Hill FCD Komposisi 2,289 0,17 0,0547 0,0444
Material Aktual 0 0 00 0,09 0,1043 0,072
Unsur
2,427% 1,35 0,045 0,085 0,06
C 1,543%
Si 0,183% 2,67 0,112 0,267 0,669 Hill FC
Mn 0,008% Hill FCD
S 0,018% 3,3 0,141 0,316 0,669
P 0,037%
Cr 0,127% Komposisi Hill FCD Berat % Customer
Cu 0,005% Target Material
Al 0,006% (Kg) Furnace PT Metloy
Sn 0,004% 3,90% No Additive PT Metloy
Ni 2,00% 38 2,10% PT Metloy
0,25% 1 Arang Batok 12 0,65% PT Metloy
0,015% 2 Carburizer PT Metloy
0,025% 3 FeSi 2 0,11%
0,08% 4 FeMn 0,22 0,01%
0,20% 5 FeCr 1,87 0,10%
0,01% 6 Cu 0,00%
0,01% 7 SiC
0,01%
Cost Material Charging
Material Harga Mat Cost Prod
5100
Scrap Low 1530000
Scrap High 4200 0
3900
Kawat 6500 1680000
Gram 17000 0
Carburizer 14700
FeSi 19000 246257
FeMn 77000 199969
FeCr 29400
FeCu
Total 4106
144210
3833942
31
PT. PRIKAST METAL INDONESIA Rev No : E-07-PMI-X-2015
LAPORAN ENGINEERING PROCESS Dept : Engineering Processs
Date : OctoObecrtober
C. Material FC (kapasitas 5 ton)
Kapasitas Furnace : 4800 Kg
No Material Charging Berat Persentase Komposisi Material Charging (%) Customer
(Kg)
Berat C Si Mn S P Cr Cu Al Sn Ni PT Metloy
PT Metloy
1 Scrap Auto 500 10% 0,11% 0,022% 0,15% 0,012% 0,017% 0,023% 0,013% 0,020% 0,00010% 0,0040%
2 Scrap high Mn 0% 0,14% 0,036% 0,48% 0,0063% 0,011% 0,070% 0,006% 0,019% 0,00% 0,032% PT Metloy
3 Non Auto 0 0% 0,00% 0,000% 0,00% 0,000% 0,000% 0,00% 0,00% 0,000% PT Adhikarya
4 Kawat 420 9% 0,43% 0,06% 0,18% 0,004% 0,009% 0,015% 0,23% 0,020% 0,000% 0,000%
180 4% 0,00010% 0,00060% PMI
5 Gram 1700 35% 3,50% 2,25% 0,65% 0,03% 0,03% 0,25% 0,25% 0,010% PMI
6 Return FC 2000 42% 3,45% 2,30% 0,65% 0,03% 0,03% 0,25% 0,25% 0,010% 0,000% 0,000% PMI
7 Hill (FC) 0% 3,59% 1,90% 0,64% 0,009% 0,018% 0,065% 0,18% 0,000% 0,009% 0,005%
0 100% 4,11% 2,06% 0,27% 0,009% 0,017% 0,012% 0,21% 0,000% 0,009% 0,005%
Hill (FCD)
0,01% 0,006%
4800 Berat Aktual (Kg)
Komposisi Material Charging - Furnace(Kg)
C Si Mn S P Cr Cu Al Sn Ni
0,55 0,11 0,75 0,06 0,085 0,115 0,065 0,1 0,0005 0,02
0 0 0 0 0
0 0 0 0 00 0 0 0 0
1,806 0,252 0 0 00 0 0,084 0,00042 0,00252
6,3 4,05 0,018 0 0
39,1 0,756 0,0168 0,0378 0,063 0,966 0,17
58,65 38 0,153 0,085
71,8 1,17 0,054 0,054 0,45 0,45 0 0,18 0,1
0 0 0
0 81,512 11,05 0,51 0,51 4,25 4,25 0,372 0
139,106 43,26 0,288 0,33392 0,20752
12,8 0,18 0,36 1,3 3,6 0,1535 0,105
65,5
0 0 00 0
26,526 0,8208 1,0468 6,178 9,331 Hill FC
Hill FCD
12,97 0,624 0,649 4,815 4,765
Hill FC Komposisi Komposisi Adjusment Berat % Customer
Material Aktual Target Material
Unsur (Kg) Furnace PT Metloy
2,898% 3,45% No Additive PT Metloy
C 1,698% 2,00% 27 0,56% PT Metloy
Si 0,553% 0,65% 1 Arang Batok 19 0,40% PT Metloy
Mn 0,017% 0,020% 2 Carburizer PT Metloy
S 0,022% 0,030% 3 FeSi 6 0,13%
P 0,129% 0,25% 4 FeMn 9 0,20%
Cr 0,194% 0,20% 5 FeCr 0 0,01%
Cu 0,008% 0,03% 6 Cu
Al 0,007% 0,01% 7 SiC 0,00%
Sn 0,004% 0,01%
Ni
Cost Material Charging
Material Harga Mat Cost Prod
Scrap Low 5100 2550000
Scrap High 4700 0
4200
Kawat 3900 1764000
Gram 6500 702000
Carburizer 17000 175726
FeSi 14700 328395
FeMn 19000 91610
FeCr 77000 178416
FeCu 29590
Total Rp 5.819.737
32
PT. PRIKAST METAL INDONESIA Rev No :E-07-PMI-X-2015
LAPORAN ENGINEERING PROCESS
Dept : Engineering Process
Date : OctoObecrtober
D. Material FC (kapasitas 2 ton)
Kapasitas Furnace : 1800 Kg
No Material Charging Berat Persentase Komposisi Material Charging (%) Customer
(Kg)
Berat C Si Mn S P Cr Cu Al Sn Ni PT Metloy
PT Metloy
1 Scrap Auto 300 17% 0,11% 0,022% 0,15% 0,012% 0,017% 0,023% 0,013% 0,020% 0,00010% 0,0040%
2 Scrap high Mn 0% 0,14% 0,036% 0,48% 0,0063% 0,011% 0,070% 0,006% 0,019% 0,00% 0,032% PT Metloy
3 Non Auto 0 0% 0,00% 0,000% 0,00% 0,000% 0,000% 0,00% 0,00% 0,000% PT Adhikarya
4 Kawat 220 12% 0,43% 0,06% 0,18% 0,004% 0,009% 0,015% 0,23% 0,020% 0,000% 0,000%
4% 0,00010% 0,00060% PMI
5 Gram 80 39% 3,50% 2,25% 0,65% 0,03% 0,03% 0,25% 0,25% 0,010% PMI
6 Return FC 700 28% 3,45% 2,30% 0,65% 0,03% 0,03% 0,25% 0,25% 0,010% 0,000% 0,000% PMI
7 Hill (FC) 500 0% 3,59% 1,90% 0,64% 0,009% 0,018% 0,065% 0,18% 0,000% 0,009% 0,005%
100% 4,11% 2,06% 0,27% 0,009% 0,017% 0,012% 0,21% 0,000% 0,009% 0,005%
Hill (FCD) 0
0,01% 0,006%
1800 Berat Aktual (Kg)
Komposisi Material Charging - Furnace(Kg)
C Si Mn S P Cr Cu Al Sn Ni
0,33 0,066 0,45 0,036 0,051 0,069 0,039 0,06 0,0003 0,012
0 0 0 0 0
0 0 0 0 00 0 0 0 0
0,946 0,132 0 0 00 0 0,044 0,00022 0,00132
2,8 1,8 0,008 0 0
16,1 0,396 0,0088 0,0198 0,033 0,506 0,07
24,15 9,5 0,063 0,035
17,95 0 0,52 0,024 0,024 0,2 0,2 0 0,045 0,025
0
0 27,598 4,55 0,21 0,21 1,75 1,75 0,182 0 0
46,176 17,966 0,138 0,10852 0,07332
27,28 3,2 0,045 0,09 0,325 0,9 0,0633
0,047
0 0 00 0
9,116 0,3238 0,3948 2,377 3,395 Hill FC
Hill FCD
5,52 0,27 0,285 2,019 1,989
Hill FC Adjusment
Unsur Komposisi Komposisi No Material Berat % Customer
Material Aktual Target Additive
C (Kg) Furnace PT Metloy
Si 2,565% 3,45% PT Metloy
Mn 1,533% 2,00% 1 Arang Batok PT Metloy
S 0,506% 0,65% PT Metloy
P 0,018% 0,020% 2 Carburizer 16 0,90% PT Metloy
Cr 0,022% 0,030% 11 0,62%
Cu 0,132% 0,25% 3 FeSi
Al 0,189% 0,20% 3 0,19%
Sn 0,010% 0,03% 4 FeMn 3 0,19%
Ni 0,006% 0,01% 0 0,02%
0,004% 0,01% 5 FeCr
0,00%
6 Cu
7 SiC
Cost Material Charging
Material Harga Mat Cost Prod
Scrap Low 5100 1530000
Scrap High 4700 0
4200
Kawat 3900 924000
Gram 6500 312000
Carburizer 17000 105618
FeSi 14700 190445
FeMn 19000 50646
FeCr 77000 65060
FeCu 22550
Total Rp 3.200.320
33
PT. PRIKAST METAL INDONESIA Rev No :E-08-PMI-X-2015
LAPORAN MAINTENANCE
Dept : Maintenance
Date : October
8.1 Lost time Mesin
Jumlah waktu produksi yang hilang akibat adanya suatu mesin atau equipment yang
mengalami kerusakan
Grafik bulanan lost time mesin molding dan melting
Jan Feb GMraafrikAbpurlaMnaany Jluonst tJiuml e AmuegsiSnemp oOldcitngNdoavnDmecelting
200 0 0 0 0 0 0 10 5 18 0 107,82
1180 10 10 10 10 10 10 10 10 10 10 10
16
14
% 12 10,28
10
8
65
4
20 0 0 0 0 0 0 0 0
0 Dec
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov
Lost time mesin di bulan Oktober sebesar 17,82% (data ditambahkan
dengan mesin SHB), lost time tampa mesin SHB sebesar 4,73%
Dengan jam kerja 285 jam(17100 menit) dan total lost time 3048 menit
Grafik lost time per Line Produksi
OktoberDisamtFicuarcneSandaCpnretlanshobolatsshtob0ol1atCsto0m2pressor
#14#,0%## ## ## ## ## ## 12,3%
12,0%
21204,0%283 11 100 ## 315 15
#8#,0%## ## ## ## ## ## ##
#6#,0%## ## ## ## ## ##
4,0% 1,8% 2,2% 2,5%
2,0%
0,0% 0,1% 0,8% 0,1%
Lost Time tertinggi berada di line shootblast 01 melebihi target yaitu 12,3%
34
PT. PRIKAST METAL INDONESIA Rev No : E-08-PMI-X-2015
Dept : Maintenance
LAPORAN MAINTENANCE Date : October
Grafik lost time per menit 817
a. Okt 04
1Okt20 Ok3t 0LOokstt0 Time Total
1200 Disa O0kt 004 P90erminggu
ace13F4urn09 00
1000 Slantd1p196207 0 56
800 e Cra2n0 25 45 30 760
Axis Title 600 561 SHB 0 510 375 655 541
400 2560 SHB 0 120 90
200 Cesoomrpr60 045 15 10
0996 541 760 817
0
Okt 01 Okt 02 Okt 03
Axis Title
Lost Time mesin tertinggi pada Okt 01 sebesar 996 menit
b. 1Okt20 Ok3t 0 OLkot 0st Time Mesin per Minggu
700 996 54O1k7t 6004 817 655
600 560 Disa
510 Furnace
375 Sandplant
500 Crane
SHB 01
400 SHB 02
Compresor
300
207
200 134 120 90 90 5656 4510
100 25 0 0 2045 0 0 0 30 60
0 15
Okt 01 Okt 02 Okt 03 Okt 04
Lost Time mesin tertinggi di dominasi pada mesin shoot blast 01
tiap minggunya mencapai 655 menit pada okt 03
35
PT. PRIKASPTTM. EPTRALIKINADOSNTEMSIAETALRIevNNDo :ONESIA Rev No : PT. PRIKAST METAL INDONESIA
LAPORAN MAINTENANCE
LAPORAN MLAAINPTOENRAANCNE MAINTDDeaEpteNt :: AM0N4a-iCnNtoeEnv-a1n5ce Dept : Maintenance
1,4 Detail Problem mesin Date : 4-Nov-15 8.2 Detail Problem mesin
Mesin Problem Lost Time Qty Muncul Cause Temp Action Fix Action Status
Disa Operasi 5 Eror 38 mnt 1 x Solenoide valve HY 12 mati Ganti solenoide valve Closed
Setting Cross Joint 70 mnt 1 x Pin guide geser Cek cross joint setiap akhir shift 1 Closed
Pattern Lock Mendem 26 mnt 1 x Patern lock AUS Modifikasi, pembuatan stopper lock Closed
Operasi 3 Eror 50 mnt 2 x Kabel relay 21A putus, kabel sudah kakJumper power Search problem dan penggantian kabel Closed
Pin guide SP mendem 40 mnt 2 x Las'an pin guide pecah(lock guide) Las ulang Pembuatan stopper di dudukan guide Closed
Furnace F 01 kontak point lengket 11 mnt 1 x Predictive pending, kawat las repair habis Repair kontak point dan ganti Closed
SandplantGreeting shake out lepas 57 mnt 2 x Welding dan repair greeting Closed
DS 19 suport motor patah 86 mnt 1 x Pembuatan suport baru Closed
Drum DS 08 shaft patah 120 mnt 1 x Welding dan repair shaft Closed
Motor shake out trip 20 mnt 1 x Kabel power motor putus Penyambungan kabel power motor Closed
Crane Crane transfer trouble 25 mnt 1 x Kabel pendant putus Penyambungan kabel pendant Closed
Crane triming trouble 45 mnt 1 x Roda crane cross AUS Modifikasi Crane dan ganti roda baru Closed
SHB 01 Link, Pin, Bushing patah/AUS 1950 mnt 21 x Spare part stock kosong repair link dan ganti pin paPkerbmaiunt aan spare parts link Open
plate Vibrating table patah 150 mnt 2 x Penggantian plate vibrating Closed
SHB 02 pintu shb tidak mau tutup 45 mnt 2 x Solenoide valve kebakar Ganti solenoide Closed
House impeller bolong 60 mnt 1 x Ganti plate linear baru Closed
Blade impeller bawah AUS 120 mnt 1 x Ganti blade impeller baru Closed
House Bearing screw AUS 60 mnt 1 x Repair house bearing Permintaan bearing unit 212 Closed Rev No : E-08-PMI-X-2015
Dept : Maintenance
Comp Compresor sulair trip (over heat) 25 mnt 2 x Stock spare parts filter kosong Cleaning setiap minggu Open Date : October
36
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