Advanced Series Team AED
Sep 08, 2015
Advanced SeriesTeam AED
CUSTOMER BOUGHT THE MACHINES
COMPLAINS ON PERFORMANCE
OFR DONE
EXISTING PROJECT
CUSTOMER
CONSIDERING TO BUY
OFR DONE
FLEET DEMAND NEW
PROJECT
Proses OFR
Data Proyek & faktor pembatas pemilihan alat berat
Pemilihan Type dan model alat berat
Perhitungan jumlah armada alat berat
Check pencapaian produksi armada vs target produksi
Perhitungan biaya produksi dan investasi
Check sensitivitas terhadap hari kerja
DATA-DATA YANG DIPERLUKAN
Data Proyek : Target Produksi, striping ratio,
Karateristik material (Density bank/loose,
Swell factor, kekerasan)
Lay out penambangan Lay out penambangan
Jadwal Kerja
Process sequent
Other (regulasi, curah hujan, ketinggian, dll)
Condition checkCondition check
Job Site VisitJob Site VisitJob Site VisitJob Site VisitDiscuss with customerDiscuss with customer
OFR MAKING
Current operation checkCurrent operation checkJob site measurementJob site measurement
Actual dataActual dataMaterial, Haul road, mapMaterial, Haul road, map
Cycle time, data proyek,Cycle time, data proyek,
dlldll
Actual dataActual dataMaterial, Haul road, mapMaterial, Haul road, map
Cycle time, data proyek,Cycle time, data proyek,
dlldll
Data ReviewData ReviewData ReviewData ReviewOFR MAKING
AnalysisAnalysisAnalysisAnalysisOFROFR
OFR MAKING
Fleet Production Cost
ReportingReportingReportingReportingReportingReportingReportingReportingOFR MAKING
Presentation
to customer
Presentation
to customer
OFR Tambang BatubaraData-data proyek :- Customer : PT Angkasa Megah- Bidang usaha : Kontraktor tambang batubara- Pemilik KP : PT Satya Nugraha- Area kerja : Batulicin- Jenis kontrak : Double rit- Target produksi : 50,000 ton/bulan- Stripping ratio : Rata-rata 1:5 - Tidak memerlukan land clearing
Jarak angkut :Jarak angkut :- Overburden : 1.5 km- Coal : 2 km (pit-stockpile)
10 km (stockpile-port)- Profil jalan : OB : rata-rata uphill 5%, max 10%
Coal : Pit-stockpile : rata-rata uphill 4%, max 10%Stockpile-port : rata-rata flat, max 2%
Material- Jenis material OB : soil & sandstone- Densitas : OB : 2.4 t/bcm; 1.7 t/lcm
Coal : 1.3 t/bcm; 0.9 t/lcm- Jumlah seam : 1 seam- Tebal minimum : 1 meter
OFR Tambang Batubara
Sistem Penambangan- Penggalian : OB : 50% ripping minta UT melakukan test seismic
50% direct excavatingCoal : direct excavating
- Pemuatan : OB : track tipe loaderCoal : Pit: track tipe loader
Stockpile : Wheel tipe loader- Pengangkutan : dump truck
Jadwal kerja- Jam kerja efektif : 18 jam/hari- Jam kerja efektif : 18 jam/hari- Hari kerja rata-rata : 25 hari/bulan
300 hari/tahun- Hari kerja hujan : 20 hari/bulan- Hari kerja kering : 30 hari/bulan- Target time efficiency : 90%- Target availability alat : 90%
Pricing- OB removal : USD 2.4 /bcm- Coal getting&loading : USD 1 /ton- Coal hauling : USD 0.1 /ton.kmHarga diatas sudah termasuk road maintenance dan kegiatan mining supporting lainnya
Lay out tambang
Port
Ponton
Jalan Raya
Simpang km 5Hauling Road 5 km
PitStockpile & Crushing plant
Hauling Road 5 km
2 km
Desa Domba
Desa Biribiri
Disposalarea
1.5 km
OFR Tambang Batubara
Regulasi setempat- Tidak boleh ada peledakan/blasting di pit dekat kampung- Trailer tidak boleh menyeberangi jalan raya umum, panjang kendaraan max 12 m, axle yang dibolehkan 8x4
- Tidak diperkenankan membuat bypass atau flyover- Berat max kendaraan & muatan yang lewat jalan raya 50 ton
Financing- Pembiayaan alat berat : 20% dari perusahaan 80% dari bank/leasing company- Alat 100% baru
Local Cost- Fuel Price :Rp.5,000.-- Oil Cost :Rp.12,000.-- Grease :Rp.20,000.-- Kurs :Rp.9,3000.- / US$- Operator :1 US$/jam
Penentuan Tahapan Kegiatan Penambangan
Overburden Removal Digging/Ripping Bulldozer Pemuatan Excavator Hauling Dumptruck Spreading at disposal Bulldozer
Coal Production Digging-loading Excavator Digging-loading Excavator Hauling to stockpile Dump truck Crushing Coal crusher Loading to truck Wheel Loader Hauling to port Dump truck Loading to ponton Hoper & Belt Conveyor
Perawatan Jalan Grading Motor Grader Dust suppression Water truck
Pembagian Kerja Alat Berat
Produksi
Langsung melakukan kegiatan produksi alat gali, muat, angkut
Support
Membantu kelancaran proses produksi road maintenance, ditching, dll
Bulldozer for Ripping
Bulldozer for RippingHasil tes seismik :Cepat rambat max 2,635 m/s
2,635
2,635
Bulldozer yang paling tepat adalah D375A-5
Excavator for Loading - Overburden
Faktor pembatas :
- Kedalaman ripping bulldozer, D375A-5 : 1.44 m
- Ketinggian tumpukan material hasil gusuran D375A-5 : 2.26 m
Alternatifnya : Alternatifnya :
PC800-7, PC1250-7
Faktor yang mempengaruhi pemilihan :
- Seam minimum : 1 m
- Tinggi bucket
PC400LCSE-7 : 1.58 m
PC300-7 : 1.49 m
Excavating & Loading - Batubara
PC300-7 : 1.49 m
PC200-7 : 1.17 m
Dump truck - overburden
Faktor yang mempengaruhi pemilihan :
Kesesuaian dengan alat muat
Ukuran bucket ukuran vessel
Jumlah bucket per trip 3 7 kali
Alternatif :
PC800 HM400
PC1250 HD465-7 or HD785-5
Dump truck batubara
(Pit Stockpile)
Faktor yang mempengaruhi pemilihan :
Kesesuaian dengan alat muat (excavator)
Dimensi Hoper 2 x 3 m
Dump truck batubara
(Stockpile Port)
Faktor yang mempengaruhi pemilihan :
Regulasi :
Maksimum 8x4
Berat bermuatan maksimum 50 ton Berat bermuatan maksimum 50 ton
Tidak boleh mengoperasikan trailer
Dimensi Hoper : 10 x 5 m
Nissan CWB520LDN 20 tScania P124CA 6x4 360 28 t
Scania P124CA 8x4 420 33 t
Loading Batubara di stockpile
Faktor yang mempengaruhi pemilihan :
- Kesesuaian dengan truck batubara- Batubara di stockpile bersifat lepas dan ringan, - Area kerja cukup luas, butuh mobilitas tinggi
Wheel Loader
dengan coal bucket
Kesesuaian dimensi wheel loader coal bucket dump truck coal body
Feeding batubara ke hoper di port
- Batubara termasuk material ringan - Bandingkan lebar blade dengan lebar hoper
Bulldozer dengan coal bladeBulldozer dengan coal blade
Lebar BladeD155A-2 : 5.3 mD275A-5 : 6.27 mD375A-5 : 7.64 m
Pemilihan Alat pendukung
Motor GraderTergantung dump truck yang bekerja
Up to HD325 : GD600 seriesHD465 series : GD700 seriesHD785 series & up : GD800 series
Manpower yang berkaitan dengan
operasional alat berat di tambang
1. OperatorJumlahnya menggunakan rumus : Jumlah alat berat x jumlah shift kerja x 1.2Jumlah alat berat untuk proyek ini adalah 26 unitJumlah shift kerja adalah 2 shift panjangMaka jumlah operator yang perlu disiapkan adalah 63 orang operator
2. Foreman2. Foreman- 1 armada 1 foreman ada 2 armada overburden dan 1 armada coal- 1 disposal area 1 foremanTotal ada 4 foreman yang perlu disiapkan
3. Checker- 1 hauling road overburden 1 checker- 1 hauling road coal 1 checkerTotal ada 2 orang checker
Penentuan alternatif alat berat
Alt - 1 Alt - 2 Alt - 3
- Ripping-dozing Bulldozer D375A-5 D375A-5 D375A-5
- Loading Hydraulic Excavator PC750SE-7 PC1250-6 PC1250-6- Hauling to Disposal Dump Truck HD325-6 HD465-7 HD785-5
- Dozing and Spreading Bulldozer D85ESS-2 D85ESS-2 D85ESS-2
Digging-loading Excavator PC200-7 PC300SE-7 PC400LCE-7Hauling to stockpile Dump truck CWB520LDN CWB520LDN CWB520LDN
OVERBURDEN REMOVAL
COAL PRODUCTION
Working Type Machine TypeMachine Model
Hauling to stockpile Dump truck CWB520LDN CWB520LDN CWB520LDN
Crushing Coal crusher
Loading to truck Wheel Loader WA320-3 WA320-3 WA320-3Hauling to port Dump truck P124 8x4 P124 8x4 P124 8x4Loading to ponton Belt Conveyor
- Grading and Leveling Motor Grader GD621R-1 GD705A-4 GD825A-2- Dust Suppression Water Truck CWB520LDN CWB520LDN CWB520LDN
ROAD MAINTENANCE
Jumlah alat berat
Productivity
Jam kerja efektif
Target produksi
Jumlah alat berat
Jumlah Kebutuhan Alat OverburdenEffective Working hours 450 hrs/month
bcm/hour bcm/month unit bcm/monthAlternative 1
- Ripping-dozing D375A-5 348.09 125,000 1 156,642
- Loading PC750SE-7 342.22 250,000 2 307,994
- Hauling to Disposal HD325-6 57.38 250,000 10 258,227
- Dozing and Spreading D85ESS-2 687.01 125,000 1 309,153
Road Maintenance
- Grading and Leveling GD621R-1 1
- Dust Suppression CWB520LDN 1
Alternative 2
AchievementWorking TypeMachine
Model
Production
CapacityNo. of Unit
Production
Target
Alternative 2
- Ripping-dozing D375A-5 348.09 125,000 1 156,642
- Loading PC1250-6 487.37 250,000 2 438,631
- Hauling to Disposal HD465-7 89.85 250,000 7 283,012
- Dozing and Spreading D85ESS-2 687.01 125,000 1 309,153
Road Maintenance
- Grading and Leveling GD705A-4 1
- Dust Suppression CWB520LDN 1
Alternative 3
- Ripping-dozing D375A-5 348.09 125,000 1 156,642
- Loading PC1250-6 487.37 250,000 2 438,631
- Hauling to Disposal HD785-5 132.65 250,000 5 298,456
- Dozing and Spreading D85ESS-2 687.01 125,000 1 309,153
Road Maintenance
- Grading and Leveling GD825A-2 1
- Dust Suppression CWB520LDN 1
Jumlah Kebutuhan Alat BatubaraEffective w orking hours 450 hrs/month
ton/hour ton/month unit ton/month
Alternative 1
Digging-loading PC200-7 65.90 50,000 2 59,309
Hauling to stockpile CWB520LDN 41.75 50,000 3 56,369
Loading to truck WA320-3 181.24 50,000 1 81,557
Hauling to port P124 8x4 35.11 50,000 4 63,205
Production
Target
No. of
UnitAchievementWorking Type
Machine
Model
Production
Capacity
Hauling to port P124 8x4 35.11 50,000 4 63,205
Alternative 2
Digging-loading PC300SE-7 194.02 50,000 1 87,308
Hauling to stockpile CWB520LDN 61.14 50,000 2 55,023
Loading to truck WA320-3 181.24 50,000 1 81,557
Hauling to port P124 8x4 35.11 50,000 4 63,205
Alternative 3
Digging-loading PC400LCE-7 246.47 50,000 1 110,909
Hauling to stockpile CWB520LDN 67.08 50,000 2 60,374
Loading to truck WA320-3 181.24 50,000 1 81,557
Hauling to port P124 8x4 35.11 50,000 4 63,205
Biaya Produksi
Total biaya produksi alat berat
Total pencapaian produksi alat berat
Biaya produksi alat berat
Unit US$/hr US$/month bcm/month US$/bcm
Alternative 1
- Ripping-dozing D375A-5 1 91.7 338,483 250,000 1.35
- Loading PC750SE-7 2 61.2
- Hauling to Disposal HD325-6 10 46.4
- Dozing and Spreading D85ESS-2 1 29.1
Road Maintenance
- Grading and Leveling GD621R-1 1 24.4
- Dust Suppression CWB520LDN 1 20.4
Alternative 2
Production
Target
Production
Cost
Owning and
Operating CostTotal CostWorking Type
Machine
Model
No. of
Unit
Biaya Produksi Alat Berat Overburden
Alternative 2
- Ripping-dozing D375A-5 1 91.7 362,626 250,000 1.45
- Loading PC1250-6 2 81.5
- Hauling to Disposal HD465-7 7 66.5
- Dozing and Spreading D85ESS-2 1 29.1
Road Maintenance
- Grading and Leveling GD705A-4 1 35.9
- Dust Suppression CWB520LDN 1 20.4
Alternative 3
- Ripping-dozing D375A-5 1 91.7 367,359 250,000 1.47
- Loading PC1250-6 2 81.5
- Hauling to Disposal HD785-5 5 90.0
- Dozing and Spreading D85ESS-2 1 29.1
Road Maintenance
- Grading and Leveling GD825A-2 1 62.1
- Dust Suppression CWB520LDN 1 20.4
Effective working hours 450 hrs/month
Unit US$/hr US$/month ton/month US$/Ton
Alternative 1
Digging-loading PC200-7 2 15.94 90675 50,000 1.81
Hauling to stockpile CWB520LDN 3 20.64
Loading to truck WA320-3 1 24.11
Hauling to port P124 8x4 4 20.90
Production
CostWorking Type
Machine
Model
No. of
Unit
Owning and
Operating Cost
Production
TargetTotal Cost
Biaya Produksi Alat Berat Batubara
Hauling to port P124 8x4 4 20.90
Alternative 2
Digging-loading PC300SE-7 1 26.69 79053 50,000 1.58
Hauling to stockpile CWB520LDN 2 20.64
Loading to truck WA320-3 1 24.11
Hauling to port P124 8x4 4 20.90
Alternative 3
Digging-loading PC400LCE-7 1 41.96 85926 50,000 1.72
Hauling to stockpile CWB520LDN 2 20.64
Loading to truck WA320-3 1 24.11
Hauling to port P124 8x4 4 20.90
CRITERIA DRY SEASON NORMAL RAINY SEASON
Working Hours (hrs/month) 540 450 360
Overburden (bcm/month) 309,872 258,227 206,581
Coal (ton/month) 66,028 55,023 44,019all currency in US$
Overburden Removal ?? ?? ??
Coal Getting ?? ?? ??
Coal Hauling ?? ?? ??
Total Cash In ?? ?? ??
Production
CASH IN
Sensitivitas terhadap jam kerja efektif
Total Cash In ?? ?? ??
Salary ?? ?? ??
Fuel & Consumable ?? ?? ??
Operating cost ?? ?? ??
Owning cost ?? ?? ??
Bank Loan ?? ?? ??
Insurance ?? ?? ??
Total Cash Out ?? ?? ??
Tax 3% ?? ?? ??Surplus/Deficit per month ?? ?? ??
CASH OUT
Data
Pricing OB : $ 2.4 /bcm- Coal getting & loading: $ 1 /ton- Coal hauling : $ 0.1 /ton.km
Employee Operator : $ 54 /month.operator Operator : $ 54 /month.operator Foreman : $ 97/month/foreman Supervisor : $ 151 /month.supervisor
Fuel Qty : 613 liter/jam Price : Rp.5,000/liter
Consumable good : $ 185 /jam Bank Loan : $ 6,003,800 dengan rate 9% Insurance : 0.5%
Sensitivitas terhadap jam kerja efektifCRITERIA DRY SEASON NORMAL RAINY SEASON
Working Hours (hrs/month) 540 450 360
Overburden (bcm/month) 309,872 258,227 206,581
Coal (ton/month) 66,028 55,023 44,019
CASH IN all currency in US$
Overburden Removal 743,693 619,744 495,796
Coal Getting 83,430 69,525 55,620
Coal Hauling 91,015 75,846 60,676
Operation 918,138 765,115 612,092
Other Income - - -
Production
Other Income - - -
Total Cash In 918,138 765,115 612,092
120% 100% 80%
Salary 12,215 12,215 12,215
Fuel & Consumable 421,682 351,402 281,121
Operating cost 433,897 363,617 293,336
119% 100% 81%
Owning cost 209,180 209,180 209,180
Bank Loan 206,053 206,053 206,053
Insurance 3,127 3,127 3,127
Total Cash Out 643,077 572,797 502,517
Tax 3% 8,252 5,770 3,287
Surplus/Deficit per month 266,809 186,548 106,288
143% 100% 57%
CASH OUT