PT Petrokimia Gresik - Innovation in Transportation & Logistics

Name of Organization / Company: PT Petrokimia Gresik, Gresik, Jawa Timur, Indonesia
Category: Award for Innovation in Transportation & Logistics

Entry Title: New Interlock System For Continuous Ship Unloader Of PT Petrokimia Gresik (PG)

Essay

Indonesia is an agrarian country where most of its population make a living in agriculture. Based on data obtained from the Central Statistics Agency (BPS) in 2018, the number of farmers reached 30.46% of the total workforce in Indonesia or around 38.7 million. As an agricultural country, up until now the majority of Indonesia's population has utiliz ed natural resources to support their livelihoods, primary based on agricultural sector in gaining national food security. PG as the largest fertiliz er company, with most diversified product in Indonesia, reinforces the national food security program in accordance with the current Indonesian Government program.

For the purpose of supporting to support the program, PG has constructed an International Port which is assigned to distribute raw materials to the fertiliz er production process. In 2017 there was a decline in availability of internal loading devices, called Continuous Ship Unloader (CSU-1) with availability values for May-July 2017 only 78% while the Key Performance Indicator had been settled to 90%. As the figured declined, PG has suffered a loss of 2.9 billion rupiah and lost material loading time for 153.3 hours. Moreover, the low availability value also results in a low level of employee satisfaction at level 2 and poses health risks in the form of high dust leakage exposure for 137.3 hours in the PG's workforce.

Innovation Concept:

From the analysis using the Ishikawa Diagram and Failure Mode and Effect Analysis (FMEA) methods the main cause of the low availability value was because the hydraulic start interlock system at CSU-1 was not provided.

Thus it caused an operating error during the CSU-1 operation, which finally resulted in a high breakdown at CSU-1 and a very drastic decrease in Availability value. To boost the availability value of CSU-1, PG innovated by creating a new interlock system on the CSU-1 hydraulic system. The new interlock system is made by engineering the operator's input signal to be sent to the PLC (Programmable Logic Control), make it possible for the new interlock system is to hold input signals and avoid all errors during operation. The concept of innovation is based on the principle of "Poka Yoke" which is a technique to avoid simple mistakes caused by humans or workers by preventing it directly from the root cause and having a very large impact on an activity. This interlock system is a new and reliable system which is able to prevent the occurrence of errors in operations that have a direct impact on the low availability value.

Impact:

Referring to the results of the analysis after making this innovation, the value of availability was successfully increased to 99.6% or up by 21.6%. Not only that, PG was able to reduce losses by 60.4 million rupiah and one-year savings of 13.6 billion rupiah. The satisfaction level of operators also experienced a significant increase to level 4 which was in line with the decline in the risk of health hazards in the form of dust leak exposure to 0 hours or no more dust leaks at PG International Port. The new hydraulic interlock system also has the potential to be used in similar devices such as other large companies, such as Semen Gresik, Holcim and many others.

In order to maintain the consistency of this innovation and maintain the performance of CSU-1, standardization has been established in the form of Interlock System Installation at the CSU-1 Operator Start Change Over switch and CSU Unit Operational Standards which have been approved by the International Port Manager of PG.

Awards: PG earned the Platinum Award at the 2018 National Innovation Convention in Batam. In this event, PG strives against hundreds of companies as competitors throughout Indonesia and won the second highest award, Platinum.

LINKS:

URL 1: https://www.youtube.com/watch?v=8F-GPwigj5E

URL 2: www.petrokimia-gresik.com