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Journal : International Journal of Computer and Information System (IJCIS)

Optimization of Hydraulic Pump Unit Control Communication with Seven Tools Method to Reduce Raw Mill Downtime In PT. Semen Gresik Fauzan, Zulfahmi; Indriastiningsih, Erna; Primasanti, Yunita; Nugrahadi, Bekti
International Journal of Computer and Information System (IJCIS) Vol 6, No 1 (2025): IJCIS : Vol 6 - Issue 1 - 2025
Publisher : Institut Teknologi Bisnis AAS Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.29040/ijcis.v6i1.222

Abstract

The Indonesian cement industry faces challenges in improving operational efficiency amid increasing competition. One critical factor in cement production is the operational stability of the Raw Mill, which depends on the performance of the Hydraulic Pump Unit. This study aims to optimize control communication in the Hydraulic Pump Unit to reduce downtime in the Raw Mill area of PT. Semen Gresik. Using the Seven Tools method, the study identified communication disruptions as the primary cause of downtime. Key issues include unreliable remote I/O PLCs, high operating temperatures, excessive loops, poor grounding, and procedural errors. To address these problems, the study proposes replacing remote I/O PLCs, adding Junction Boxes, relocating PLCs to a control panel room, redesigning the network topology, switching from Ethernet to Profibus, improving grounding, conducting training, and updating maintenance standards. The implementation of these solutions successfully reduced Raw Mill downtime, improved production efficiency, and enhanced control system reliability by creating new operational standards. These findings highlight the importance of effective control communication in maintaining stable and efficient cement production operations.
Analysis of Behavior-Based Safety Criteria with the Rate of Work Accidents at Power Plants Units 3, 7 and 8 East Java Yunanto, Bekti; Indriastiningsih, Erna; Trisna Devi, Anita Oktaviana; Nugrahadi, Bekti
International Journal of Computer and Information System (IJCIS) Vol 6, No 2 (2025): IJCIS : Vol 6 - Issue 2 - 2025
Publisher : Institut Teknologi Bisnis AAS Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.29040/ijcis.v6i2.227

Abstract

Occupational safety and health are important factors in the steam power generation industry which has a high risk of work accidents. The implementation of behavior-based safety at coal-fired power plants is useful for reducing the incidence of accidents through intervention on worker behavior. This study aims to analyze the relationship between behavior-based safety criteria and the rate of work accidents at PLTU Units 3, 7, and 8 in East Java. This study uses a quantitative approach with a cross-sectional design. Primary data was collected through questionnaires distributed to 178 workers, while secondary data was obtained from company safety reports. The results of the study show that there is a significant relationship between behavior-based safety and the rate of work accidents through the definition factors of safe/unsafe behavior, training, basic performance, reinforcement, feedback, goal setting, and reviews in PLTU Units 3, 7, and 8 workers in East Java. This variable contributes to increasing workers' awareness of safety and reducing the number of work accidents. Meanwhile,  the ownership variables) and observation did not have a significant relationship with work accidents, indicating the need for increased active worker participation and the effectiveness of follow-up from safety observations. The conclusion of this study is that behavior-based safety is an effective approach in reducing work accidents at coal-fired power plants, with factors such as safe/unsafe behavior, training, basic performance, reinforcement, feedback, goal setting, and review plays an important role in improving occupational safety. Companies need to strengthen training programs and monitoring worker behavior to achieve the zero accident target.