Project Overview

PREPARE BY DUDDY ARISANDI, S.T. (JULY'01)

Project OverviewProject Overview

MAINTENANCE MAINTENANCE MECHANIC MECHANIC TECHNOLOGYTECHNOLOGY

VISION & MISSIONVISION & MISSION

OBJECTIVEOBJECTIVE

””PBE” PROCESS PBE” PROCESS

COMPETENCYCOMPETENCY

SUBJECTSUBJECT

IMPLEMENTATIONIMPLEMENTATION

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Vision & MissionVision & MissionInstructions:

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VISIONTO BECAME THE SPEARHEAD OF EDUCATION AND IMPLEMENTATION OF MAINTENANCE BASIC SKILL TECHNOLOGY

MISSIONTO DEVELOP HUMAN RESOURCES WHO ARE ABLE TO MAINTAIN, REPAIR AND BUILT MACHINE TOOLS, GENERAL MACHINE AND SUPPORTING EQUIPMENT; AND ABLE TO ASSIMILATE WITH NEW CONCEPT & TECHNOLOGY IN MAINTENANCE

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ObjectiveObjective

TO TEACH STUDENT IN MAINTENANCE BASIC SKILL CONCEPT AND PROCEDURE IN ORDER TO HAVE APPROPRIATE COMPETENCY WITH INDUSTRY AND HAVE PROFESSIONAL SKILL

TO MAINTAIN, REPAIR AND BUILT MACHINE BASED ON STANDARD ACCEPTANCE TEST

TO LEARN, DEVELOPING AND ARRANGE IMPLEMENTATION OF NEW CONCEPT IN MAINTENANCE SUCH AS CONDITION BASED MONITORING, MAINTENANCE CONTROL SYSTEM, CNC TECHNOLOGY, ETC

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””PBE” ProcessPBE” Process

INPUTMAINTENANCE

MECHANIC TECHNOLOGY

OUTPUT

•STUDENT

•PRODUCT

•MODULAR TRAINING

•ENGINEERING

•CONSULTATION

•COMPETENCY

•PROFESSIONAL SKILL

•PRODUCT QUALITY

•CUSTOMER SATISFACTION

•CURRICULUM

•LECTURE

•TEACHING AID

•MODULE

•MACHINE

•TOOLS &

MEASURING INSTRUMENT

•SUPPORTING DATA

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CompetencyCompetency

HOW TO DETERMINE COMPETENCYIN MAINTENANCE MECHANIC TECHNOLOGY ?

COMPETENCY IN MAINTENANCE MECHANIC TECHNOLOGY BASED ON INDUSTRY NEEDED AND DEMAND

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321

CompetencyCompetencyINDUSTRY

NEEDED

PRODUCTION ORDER

TRAININGORDER

ENGINEERINGORDER

CONSULTATIONORDER

DATA FROMAPPRENTICES

LEVEL OF STUDENTCOMPETENCY

PERIOD OF TIME

MINIMUMINDUSTRY NEEDED

1. LOWER THAN INDUSTRY NEEDED2. AGREE WITH INDUSTRY NEEDED3. HIGHER THAN INDUSTRY NEEDED

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MECHANICAL DRIVE ALIGNMENT (12 %)


TRAININGORDER

SEAL MOUNTING & DISMOUNTING (1.2 %)

BEARING MOUNTING & DISMOUNTING (13.2 %)

LUBRICANT & LUBRICATION (10.8 %)

HAND SCRAPING (1.8 %)

MAINTENANCE MANAGEMENT (12 %)

MACHINE TOOLS GEOMETRICAL CHECK (7.8 %)

MECHANICAL COMPONENT REPAIR (9 %)

ARC, GAS & SPECIAL WELDING (21.6 %)

BASED ONMODULAR TRAININGDURING 10 YEARS (UNTIL FEBRUARY 2001) :•167 PACKET OF TRAINING•14 SUBJECT OF MODULAR TRAINING

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PRODUCTORDER

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ENGINEERINGORDER

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ENGINEERINGORDER


Subject in ”PBE” ImplementationSubject in ”PBE” Implementation

MAINTENANCE MAINTENANCE MECHANIC MECHANIC TECHNOLOGYTECHNOLOGY

MECHANICAL DRIVE ALIGNMENT (1 WEEK)MECHANICAL DRIVE ALIGNMENT (1 WEEK)

BEARING MOUNTING & DISMOUNTING (1 WEEK)BEARING MOUNTING & DISMOUNTING (1 WEEK)

HAND SCRAPING (1 WEEK)HAND SCRAPING (1 WEEK)

PUMP & COMPRESSOR INSTALLATION (1 WEEK)PUMP & COMPRESSOR INSTALLATION (1 WEEK)

LUBRICATE & LUBRICATION (0.5 WEEK)LUBRICATE & LUBRICATION (0.5 WEEK)

MAINTENANCE WORK / OVERHAUL (4 WEEKS)MAINTENANCE WORK / OVERHAUL (4 WEEKS)

PREVENTIVE MAINTENANCE / ME & FO (8 WEEKS)PREVENTIVE MAINTENANCE / ME & FO (8 WEEKS)

MACHINE ASSEMBLY & DISASSEMBLY (1 WEEK)MACHINE ASSEMBLY & DISASSEMBLY (1 WEEK)

MILLING & TURNING (6 WEEKS)MILLING & TURNING (6 WEEKS)

MACHINE MAKING (4 WEEKS)MACHINE MAKING (4 WEEKS)

VIBRATION ANALYSIS (0.5 WEEK)VIBRATION ANALYSIS (0.5 WEEK)

SPARE PART COMPONENT MAKING (4 WEEKS)SPARE PART COMPONENT MAKING (4 WEEKS)

PRODUCTION PLANNING & CONTROL (2 WEEKS)PRODUCTION PLANNING & CONTROL (2 WEEKS)

ALL AROUND PRODUCTION (3 WEEKS)ALL AROUND PRODUCTION (3 WEEKS)

FABRICATION (3 WEEKS)FABRICATION (3 WEEKS)

ELECTRICAL INSTALLATION (2 WEEKS)ELECTRICAL INSTALLATION (2 WEEKS)

SUBJECT FOR ALL STUDENT IN ONE YEAR (42 WEEKS)

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CompetencyCompetencyInstructions:






DATA FROM APPRENTICES

MAINTENANCE SUBJECT SKILL APPLICATION (60.9 %)

PREVENTIVE MAINTENANCE PLANNING SYSTEM(26.1 %)

CONSTRUCTION DESIGN(7.2 %)

SPARE PART MAKING & MANAGEMENT (5.8 %)

BASED ON APPRENTICESDURING 1994 - 1997 :•67 JOURNAL OF APPRENTICES•20 - 50 KIND OF INDUSTRY

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CompetencyCompetencySUPPORTING

DATAF

AB

RIC

AT

ION

(8

8.2%

)

BASED ONKIND OF ORDERDURING 1997 - 2000 R

EP

AIR

, O

VE

RH

AU

L &

M

AK

ING

M

AC

HIN

ES

(11.

8 %

)

FA

BR

ICA

TIO

N

(70%

)

RE

PA

IR,

OV

ER

HA

UL

&

MA

KIN

G

MA

CH

INE

S(3

0 %

)

FA

BR

ICA

TIO

N

(31.

6%)

RE

PA

IR,

OV

ER

HA

UL

&

MA

KIN

G

MA

CH

INE

S(6

8.4

%)

FA

BR

ICA

TIO

N

(4.8

%)

RE

PA

IR,

OV

ER

HA

UL

&

MA

KIN

G

MA

CH

INE

S(9

5.2

%)

1997 1998 1999 2000

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SubjectSubjectGENERAL SUBJECT

BASIC ENGINEERING SUBJECT

NO SUBJECT

T P T P T P T P T P T P

1 RELLIGION 1 1

2 PANCASILA (STATE OF PHILOSOPHY) 2 2

3 NATIONAL RELIANCE

SUB TOTAL 2 0 2 0 1 0 1 0 0 0 0 0

4TH SEM. 5TH SEM. 6TH SEM.

GENERAL SUBJECT

1ST SEM. 2ND SEM. 3TH SEM.

NO SUBJECT


4 MATHEMATICS 2 2

5 PHYSICS 1 1 1

6 SAFETY MEASURED 1 1

7 BASIC MATERIAL SCIENCE 1 1 1

8 BASIC MANUFACTURING PROCESSES 1 1 1 1

9 TECHNICAL DRAWING 1 1 1 1

10 COMPUTER PROGRAMMING 1 1

11 ENGLISH 1 1

12 BASIC ELECTRICAL CIRCUIT 1 1

13 REPORT WRITING 1 1

14 QUALITY MANAGEMENT 1 1

15 SUPERVISION 1 1

16 PROJECT WORK 2 2

SUB TOTAL 8 3 7 3 2 1 2 0 2 0 5 3

4TH SEM. 5THSEM. 6TH SEM.

BASIC ENGINEERING SUBJECT

1ST SEM. 2ND SEM. 3TH SEM.

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SubjectSubject

ENGINEERINGSUBJECT

NO SUBJECT


17 MACHINE ELEMENT 1 1 1 1

18 MATERIAL HANDLING & INSPECTION 1 1 1

19 WELDING AND SHEET METAL 1 1

20 ADVANCED MANUFACTURING PROCESSES 3 3 1 1 1 2

21 INTRODUCTION TO MANUFACTURING SYSTEM 1 1

22 PNEUMATICS AND HYDRAULICS 1 1 1

23 ADVANCED MATERIAL SCIENCE 1 1

24 ENGINEERING MECHANICS 1 1

25 STRENGTH OF MATERIALS 1 1

26 TECHNICAL MATHEMATICS 1 1

27 CAD - CAM - CNC 1 2

28 PRODUCTION PLANNING 1 1 1

29 CTS - NC - CNC 1 1

30 PRODUCTION AND INDUSTRIAL PRACTISE 3 2

31 PRODUCTION WORK 2 3

32 PLC (PROGRAMMABLE LOGIC CONTROLLER) 1 1

33 APPLIED ELECTRICITY 1 1

34 MECHANIC CONSTRUCTION 1 1

35 MAINTENANCE MANAGEMENT 2 1

36 MACHINE MAINTENANCE 1 2 1 2

37 MACHINE REPAIR 1 2 1 2

38 MACHINE BUILDING 1 1

39 SPARE PART MAKING 1 1SUB TOTAL 2 5 3 5 9 7 9 8 9 8 7 6

TOTAL SCUS 12 8 12 8 12 8 12 8 11 8 12 9

5TH SEM. 6THSEM.

ENGINEERING SUBJECT

1ST SEM. 2ND SEM. 3TH SEM. 4TH SEM.

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ImplementationImplementation

IMPLEMENTATION OF MAINTENANCESUBJECT

MECHANICAL DRIVE ALIGNMENT

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ImplementationImplementationIMPLEMENTATION OF MAINTENANCE SUBJECT

BEARING MOUNTING &DISMOUNTING

HAND SCRAPING

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MACHINE ASSEMBLY & DISASSEMBLY(INCLUDING GEOMETRICAL INSPECTION)

HAND TOOLS

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PUMP & COMPRESSOR INSTALLATION

LUBRICANT & LUBRICATION

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ImplementationImplementation IMPLEMENTATION OF MAINTENANCE SUBJECT

MILLING PRODUCTION

TURNING PRODUCTION

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ImplementationImplementationInstructions:






IMPLEMENTATION OF MAINTENANCE SUBJECT

PREVENTIVE MAINTENANCE

MAINTENANCE & REPAIR /OVERHAUL

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MACHINE MAKING

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FABRICATION(EXAMPLE: ARC WELDING PROCESS)

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FABRICATION(EXAMPLE: SHEET METAL PROCESS)

HEAT TREATMENT

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ImplementationImplementationSCHEDULE FOR MAINTENANCE SUBJECT(1 YEAR = 42 WEEKS)FOR 26 STUDENT

COIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

351 PSC MW FR PPC BU BA PR PM FK pms MF PSC HS FR MW BU bpm MF PM pms FK

COIN 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42351 PSC MW FR PPC BU BA PR PM FK pms MF PSC HS FR MW BU bpm MF PM pms FK

PSC BA

MW PR

FR PM

BU FK

PPC PPC

HS pms

bpm EI

5TH SEMESTER

6TH SEMESTER

: SPARE PART MAKING

: MAINTENANCE WORK

: BEARING & ALIGNMENT

: ALL AROUND PRODUCTION

: ELECTRICAL INSTALATION: MACHINE ASSEMBLY & DISASSEMBLY

:PREVENTIVE MAINTENANCE

: FABRICATION

: MAINTENANCE FOUNDRY

: HAND SCRAPING : MACHINE MAKING

: MILLING PRODUCTION

: TURNING PRODUCTION

: PRODUCT. PLANNING & CONT.

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ImplementationImplementationLOAD INSTRUCTOR (1 YEAR = 42 WEEKS)FOR 26 STUDENT

19 MG/ 4

(INCO)

18 MG (S1)

PT

(TK1)

PEM

(6MED)

PEM

(6MED)

PR

(STM)

PR

(STM)

PT

(TK1)

MG

(INCO)

MG (S1)

MG (S1)

MG

(INCO)

MG

(INCO)

25 26

WEEK CALENDAR PROGRAM

34 35 36 37 38 39 4022 23 24 41 42

PT

(TK1)

16 PT

(TK1)MG (S1)

15 MG

(INCO)

PT

(TK1)

PT

(TK1)

14 MG

(INCO)

PT

(TK1)

PT

(TK1)MG (S1)

13 MG

(INCO)

PT

(TK1)

PT

(TK1)MG (S1)

PT

(TK1)MG (S1)

12 MG

(INCO)

PEM

(6MEC)

MG

(INCO)

PEM

(6MED)

MG (S1) MG (S1)MG

(INCO)

MG

(INCO)

PT

(TK1)

PT

(TK1)

11 PEM

(6MEC)

PEM

(6MED)

MG (S1)

MG

(INCO)

MG

(INCO)

MG

(INCO)

MG

(INCO)

PT

(TK1)

PT

(TK1)

10 PEM

(6MEC)

PT

(TK1)

PT

(TK1)

PEM

(6MED)

PT

(TK1)

PT

(TK1)

9 PEM

(6MEC)

PT

(TK1)

PT

(TK1)

PEM

(6MED)MG (S1) MG (S1)

PT

(TK1)

PT

(TK1)

8 PT

(TK1)

PSC

(6MED)

PEM

(6MED)

PEM

(6MEC)

PEM

(6MEC)

PR

(STM)

PR

(STM)

PSC

(6MED)

PEM

(6MED)

7 PT

(TK1)

PR

(STM)

MG

(INCO)

PSC

(6MED)

PEM

(6MED)

PEM

(6MEC)MG (S1)

PEM

(6MEC)

PEM

(6MED)

PR

(STM)

PR

(STM)

PSC

(6MED)

PEM

(6MED)

MG

(INCO)

PEM

(6MEC)

PEM

(6MED)

PT

(TK1)

PT

(TK1)

MG (S1)

6 PT

(TK1)

PT

(TK1)

PSC

(6MED)

PT

(TK1)

PEM

(6MED)

PEM

(6MEC)

PSC

(6MED)

PEM

(6MED)

PT

(TK1)

PT

(TK1)

5 PT

(TK1)

PT

(TK1)MG (S1)

PSC

(6MED)

PT

(TK1)

PEM

(6MED)

PEM

(6MEC)

PEM

(6MEC)MG (S1) MG (S1)

PEM

(6MED)

PT

(TK1)

PT

(TK1)

PT

(TK1)

PSC

(6MED)

PT

(TK1)

4 PSC

(6MED)

PR

(STM)

PSC

(6MEC)

PSC

(6MEC)

PSC

(6MED)

PSC

(6MEC)

PSC

(6MEC)

PSC

(6MED)

MG (S1) MG (S1)

PR

(STM)

PR

(STM)

PSC

(6MED)

PEM

(6MED)

PSC

(6MED)

PEM

(6MEC)

PEM

(6MEC)

PEM

(6MEC)

PSC

(6MEC)MG (S1)

PSC

(6MEC)

PSC

(6MED)

PSC

(6MEC)

PSC

(6MEC)3 PSC

(6MED)

PT

(TK1)

PSC

(6MEC)

PEM

(6MED)

PSC

(6MED)

PEM

(6MEC)

PEM

(6MED)

PEM

(6MEC)

PEM

(6MEC)

PSC

(6MEC)

PT

(TK1)MG (S1)

PEM

(6MED)

2 PSC

(6MED)

PT

(TK1)

PSC

(6MEC)

PSC

(6MEC)

PSC

(6MED)

PSC

(6MEC)

PT

(TK1)

PT

(TK1)

PSC

(6MEC)

PT

(TK1)

PSC

(6MED)

PEM

(6MEC)

PEM

(6MEC)

PT

(TK1)

PSC

(6MEC)

PT

(TK1)

PEM

(6MED)

PSC

(6MED)

PEM

(6MEC)

PEM

(6MED)

1 PSC

(6MED)

PSC

(6MEC)

PT

(TK1)

PSC

(6MEC)

PSC

(6MEC)

PSC

(6MED)

PSC

(6MEC)

PT

(TK1)

PT

(TK1)

PSC

(6MEC)

PT

(TK1)

PSC

(6MED)

PEM

(6MEC)

PEM

(6MEC)

PT

(TK1)

PSC

(6MEC)

PT

(TK1)

PEM

(6MED)

PSC

(6MED)

PEM

(6MEC)

PEM

(6MED)TOTAL AVE.

15 12 9 22 11 11 11 3 9 3 133 16 5 13

27 28 29 30 31 32 33

7 202 9,62NUMBER OF STUDENTS

4 5

17

PR

(STM)

PT

(TK1)

PSC

(6MEC)

PSC

(6MEC)

PSC

(6MEC)

14 79

FOR EXAMPLE:A INSTRUCTOR

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ImplementationImplementationINSTRUCTOR AT MAINTENANCE MECHANICTECHNOLOGY

DUDDY ARISANDI, S.T.(HEAD OF MAINTENANCE MECHANIC TECHNOLOGY)

DADI KUSNADI(INSTRUCTOR)

ADE PURNAMA(INSTRUCTOR)

ANDI NOVIANDI(INSTRUCTOR)

MUHAMMAD SADIYO(INSTRUCTOR)

IYAN PURNAMA(INSTRUCTOR)

•ARC WELDING

•FABRICATION

(PAINTING)

•MACHINE

MAKING

•HEAT TREATMENT

•FABRICATION

(GAS WELDING &

SHEET METAL)

•MACHINE MAKING

•SPARE PART MAKING

•MACHINE MAKING

•PRODUCTION

•PREVENTIVE

MAINTENANCE

•PUMP INSTALLATION

•INDUSTRIAL

TRAINER

•OVERHAUL

•MACHINE MAKING

•BEARING MOUNTING & DISMOUNTING

•MECHANICAL DRIVE ALIGNMENT

•MACHINE ASSEMBLY & DISASSEMBLY

•TESTING MACHINE TOOLS

•HAND SCRAPING

•MACHINE MAKING

•INDUSTRIAL TRAINER

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ImplementationImplementationPRACTICAL EXAMPLE :

MECHANICAL DRIVE ALIGNMENT SUBJECT

STUDENT

INSTRUCTOR

MODULE

TEACHING AID

MEASURING TOOLS

SKILL,

QUALITY BASED ON INDUSTRYCOMPETENCY

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ImplementationImplementationPRACTICAL EXAMPLE :MECHANICAL DRIVE ALIGNMENT SUBJECT


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Project Overview