Reduce Cost With Tyre MANAGEMENT Scheme [PDF]

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Reduce Cost Operations with



Effective Tire Care Maintenance & Management



1 Stop Tire Services



TYRE MANAGEMENT  Tire Manajemen Sistem bertujuan agar sebuah Tire diperlakukan sesuai dengan kondisinya saat itu sehingga akan didapatkan umur Tire yang maksimal yang nantinya dapat menunjang operasional unit dalam berproduksi dan juga masalah safety.  Taukah anda bahwa biaya Tire dalam usaha Transportasi atau pertambangan terbuka adalah biaya kedua terbesar setelah biaya BBM? Maka dari itu proses pemeliharaan Tire adalah proses yang penting.Untuk itu perlu dedikasi untuk menjaga umur Tire yang panjang. Target utama adalah CPK (Cost Per Kilometer) atau Cost Per Hours (CPH) yang rendah.



 Definisi Tire Manajemen Sistem adalah sistem manajemen yang terintergrasi dalam ruang lingkup optimalisasi penggunaan Tire dalam suatu proses yang terdiri dari rangkaian kegiatan, seperti perencanaan, pengorganisasian, penggerakan dan pengendalian/pengawasan, yang dilakukan untuk menetukan dan mencapai tujuan yang telah ditetapkan melalui pemanfaatan sumberdaya manusia dan



sumberdaya lainnya.



Tyre Life Vehicle



TYRE MANAGEMENT ROLE and SYNERGY - WAREHOUSING SYSTEM - FITTING & REMOVAL - ROTATION & MATCHING - RIM MAINTENANCE



- TIRE REPAIR - PHISYCAL CONDITION CHECK - PRESSURE CHECK - SCRAP ANALYSIS



Tire SELECTION



Tire OPERATIONAL



- UNIT / VEHICLE - MAXIMUM LOAD - ROAD CONDITION - TRAVELLED DISTANCE - PATTERN - SPEED SYMBOL - LOAD INDEX - HEAT RESISTANCE - CUT RESISTANCE



-DRIVER AWARENESS SAFETY DRIVING TRAINING PROGRAM -LOAD CONDITION -ROAD CONDITION



OUTPUT    



Optimum Tire Life Time Reduce Tire Cost Reduce Operation Cost (Fuel & Spare-parts) Optimum Casing Life for Repairing



 Decrease Breakdown Time  Increase Availability Unit (Equipment)  Increase Safety & Environment



TYRE READING INSPECTIONS UNIT TYPE MACHINE UNIT BRAND TIRE SIZE TIRE BRAND TIRE POSITIONS TIRE PRESSURE TIRE CONDITIONS TIRE RUNNING SERVICES RIM CONDITIONS



FISHBONE DIAGRAM ROAD CONDITION Crankle



Flat



Asphalt Tank Car



Cold



TUR



Cost $



Check Physical Check Retread Claim New Tire



MAINTENANCE



Pattern



Trailer Prime Hot mover Retread



Skill Driver



Pressure



Analysis



Radial



Brand



Soil



Narrow



Scrap Analysis



Bias



Truck



Concrete



Broad



Lifetime Km



Dump Cargo Truck



Bus



Straight Hill



Tire



VEHICLE



Ex Repair



Knowledge Cheap but Expensive



Decision Management Monitor & Control



Logistics



Supervision Tire Crew



Expensive but Cheap Skill



PEOPLE



HIGH Tire COST



Knowledge



Routine Check Removal Tire



Dual Tire Matching & Spacing Tire Mixing Tire Record



• Driving Style & Habits • Driver Training Development



Daily check •Tire Surface Clearing •Tire Inflation Pressure -> Cold Check •Load Weight & Distributions



Monthly Vehicle Preventive Maintenance • Wheel Alignment • Balancing • Suspension System • Breakers • Engine Tune Up



REMOVAL TIRE



Tire Positioning



ROUTINE CHECK



Fitment Tire & Tire Rotations



FITMENT TIRE & TIRE ROTATIONS



SAFETY PROCEDURE



TYRE MAINTENANCE FLOW



Worn Out Tread Depth Min Removal 3 mm if Retread Tire



TYRE USING AND RECORDING



RECORD AND REPORT TYRE Tire Recording and Reporting 2 Tire Recording and Reporting 3 4.2. Pressure Check •4.2.1. Urgensi Pengecekan Pressure REPORTING 4.3. Pelepasan dan •4.2.2. Scheduling •4.2.3. Pencatatan dan Penginputan (disertai contoh form isian) •4.2.4. Analisa •4.2.5. Rencana Kerja Harian/ Mingguan •4.2.6. Plan Pemakaian Ban (2 bulanan?



Pemasangan Ban



4.4. Reporting (Pelaporan) •4.3.1. Urgensi Pelepasan dan Pemasangan Ban •4.4.1. Weekly Report (Pressure, HM •4.3.2. (Alasan Utama: Safety dan Longer Running) Tire Life) •4.4.2. Monthly Report (Pressure, HM •4.3.3. Status Pelepasan Ban (Spare, Running, Scrap Report, Pemakaian Ban) Repair, Retread, Scrap) •4.3.4. Alasan Pelepasan (Penyamaan Persepsi dan Stadardisasi Alasan Pelepasan for All Site)



TYRE COST FACTORS



Tire Cost Factors



Fuel (Diesel, Gas & Electricity)



Purchase Price Premature Removal Service Life (hours) Services Costs



Effect



Impact



Vehicle Downtime (Tire Failure, Refueling)



Driver Comfort



Scrap Tire /Disposal Safety



Non Tire Cost Factors



TEAM – KOMPETENSI – TANGGUNG JAWAB



• 1. Management Tire. • 2. Tire Maintenance. • 3. Tire Budgeting. • 4. Tire Repair. • 5. Tire Inspection. • 6. Tire Engineer.



• Persiapan dan perawatan tire shop dan perlengkapannya. • Analisa kebutuhan tenaga kerja dan pengaturan jadwal kerja. • Analisa kebutuhan peralatan dan alat pendukung kerja. • Pembuatan jadwal penggantian dan pemasangan ban. • Pembuatan jadwal pemeliharaan rim. • Pemeliharaan ban dan rim. • Pencatatan data ban dan rim. • Analisa dan pemanfaatan data. • Membuat dan merevisi SOP.



TEAM



KOMPETENSI



• Cara menjalankan Tire Management yang standard. • Cara menjalankan Tire Maintenance yang baik. • Cara Analisa performan ban dan rim untuk manajemen dan atasan. • Mengetahui proses dan cara tire/rim repair yang standard. • Melakukan dan analisa beberapa study (TKPH, Weight, GPS dst). • Audit site dan menampilkan laporan teknis.



TANGGUNG JAWAB



Target and Activity I. TARGET •Tire Availability •Administration and inventory controlled, with tire suppliers to overcome any bottle necks that could delay the supply/repair/retread of tires. The lowest possible costper-mile is achieved with a good tire management program that includes the use of quality retreads. •Minimize Down Time and Breakdown Unit •Taking a short cut of down time for tire change so that not disturb operational unit. •Safety Methods •Ensuring correct and Safety methods of tire fitment & removal, tire rotations, tire pressure and tread depth check and tire wear pattern inspections. •Properly Tire Cost II. SCOPE OF correct WORK planning and measured to get effectiveness of tire cost. Our target is a "lower cost per mile". •Giving •AREA OF WORK •1. Unit in active : All tire in Unit services •2. Tire Workshop : In Site •SERVICES •The Scope of Tire Management Services shall include:



PIC Action 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.



Provide Supply & Service Tire Replacement Tire Repair Tire Assembling/Disassembling Tire Rotation/Matching Tire Maintenance Pressure Pressure Recommendation Provide software to monitor and manage all tire data Tire Analyst and Control Management / Inventory Stock Technical Claim Information Inspection of tire for repair or scrap Wheel alignment Check



PLUS POINT + + + + + + + + + + + +



TMS Team TMS Team TMS Team TMS Team TMS Team TMS Team TMS Team TMS Team TMS Team TMS Team TMS Team TMS



Supplier



User



√ √



Operation Procedure Tire Replacement and Repair •At Site and Tire Workshop Tire Rotation •Front Tire Rotation •RTD/Tread Depth < 50 % •Alignment problem •Tire damage •Rear Tire Rotation / Matching •Matching RTD/Tread Depth •Repairable or not repairable •RTD/Tread Depth < 6 mm, remove tire for retread and mounting matching spare tire Tire Pressure Maintenance



OPERATION PROCEDURE



•At Site and Tire Workshop •Inflation monitoring and maintenance to all unit, inflate pressure to recommended level. Control Management •1.Plant site •Stock value, Ratio = 8 : 1 •Monthly yard Branding Number checks. •Quickly check by 10 minutes/unit (priority for loading unit and then breakdown unit) •Record tire damage and tire repairs •2.Tire Workshop •Tire Inventory and tire Replacement •New Tire, Stock Value Ratio 8 : 1 •Daily, Weekly and Monthly Tire Usage Report



Tire Analysis / Management •Used Tire Software to monitoring Mileage and Branding Number •SOP Tire Damage, Weekly and Monthly Report (Repairable or Scrap) •Monthly Tire Report (Tire Usage, Tire Scrap Analysis, Tire Claim, Pressure and RTD Report and Cost Tire)



Record Administrations ADMINISTRATION



• The Scope of Administrations shall include: • Daily Tire Change Record • Daily, Weekly and Monthly Tire Usage Report • Tire Inventory • Tire Damage, Tire Repair and Scrap Report • Mileage Monitoring Control • Warranty Claim Report



SISTEM AND METODE SISTEM AND METODE SERVICE TYPE, OBJECTIVE, dan SCOPE OF SERVICES



DESCRIPTIONS



1. SERVICE TYPE



1.1. Tire Management & Repair Onsite



2. OBJECTIVE



2.1. Tire Recondition for Available Tire Stock (Inventory Management) 2.2. Optimum Tire Life Time 2.3. Reduce Tire Cost – Efficiency 2.4. Decrease Breakdown Time 2.5. Increase Unit Availability 2.6. Increase Safety & Environment



3. SCOPE OF SERVICES



3.1. Tire Repair a. Monitoring Tire in service b. Inspection Tire out service c. Process Repairing Tire onsite d. Stock Repair management e. Reporting for improvement (road hazard, operating unit Truck, skill, etc)



REPORTING RECORDING • Data Base



REPORTING • Chart and Resume



BENEFIT



ALLWAYS



EVIDENT



IN THE ACT



Reporting ;  Laporan Performance ( umur pakai ban )  Laporan Perawatan Ban ( cek tekanan angin, cek tread , cek kondisi fisik )  Laporan Lingkungan Kerja ( cek kondisi operasional unit )  Analisa Ban Scrap ( jenis kerusakan dan penyebabnya )  Laporan penggunaan ban



Benefit ;  Meminimalisasi resiko pembelian ban yang tidak terkontrol  Meminimalisasi resiko tingginya break down time akibat frekwensi kerusakan ban  Mempermudah kontrol bisnis operasional  Meminimalkan HR Cost crew tire



FOR THE REDUCE



…… Tire Is Asset and Tire is Money



BENEFIT of REDUCE Cost Tyre Efek Domino terhadap perawatan ban secara baik dan benar



Presentase terhadap Total Biaya Operasional



40% 35%



15 %



35% 33%



30%



30%



25% 20%



20% 17%



15%



15%



10%



10%



5%



5%



0% Bahan Bakar



Ban



Sparepart & Oli



Tidak ada TMS



Ada TMS



Tenaga Kerja



Lainnya



Integarated Tyre Management



Repairing Service