Fine Coal Transfer Scheduling Model from Coal Mill 4K3 Machine to Kiln Indarung II/III and IV in PT Semen Padang

Siska, Purnama Sari (2020) Fine Coal Transfer Scheduling Model from Coal Mill 4K3 Machine to Kiln Indarung II/III and IV in PT Semen Padang. Diploma thesis, Universitas Andalas.

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Abstract

PT Semen Padang is one of the manufacturing industries engaged in cement industry. The production process in PT Semen Padang is generally divided into three stages, namely the Raw Mill (RM) stage, the Kiln Coal Mill (KCM) stage, and the Cement Mill (CM) stage. The company uses coal as fuel at the KCM stage. Coal as fuel is still in the form of raw coal, to smooth and dry it to become fine coal use the Coal Mill machine. Since 2013, the Coal Mill machine comes with a design capacity that is able to meet the demand of fine coal in the Kiln Indarung II/III and IV. The amount of fine coal needed depends on the Clinker's Corporate Budget Work Plan or Rencana Kerja Anggaran Perusahaan (RKAP). Currently, there is no scheduling used by the company to schedule the transfer of fine coal from Coal Mill 4K3 machine to Kiln Indarung II/III and IV. This causes a troubleshooting factor that result in a large total deviation between theoretical and actual fine coal quantity. The greater impact is that clinker production is not in accordance with the clinker’s RKAP. Lack of production leads to unreachable demand and consumer disappointment, while excess production causes an increase in inventory costs, especially when the demand is decrease. Fine coal transfer scheduling from Coal Mill 4K3 machine to Kiln Indarung II/III and IV is needed to overcome the company's problems. Scheduling model is Zero-One Integer Linear Programming with the aim of minimizing the total deviation between theoretical and actual fine coal quantity, so the clinker production is in accordance with clinker’s RKAP. Decision variables are decision to transfer fine coal (1) or not (0) on the day-i, workhour-j for Kiln-k. The scheduling model is developed from determining system characteristics, describing relevant systems using influence diagrams, determining assumptions, notations, parameters, and then formulating mathematical models. The next step is verification and validation of the model, implementation of the model using Lingo software, then analysis, and conclusion. This research resulted the mathematical model of fine coal transfer scheduling from Coal Mill 4K3 machine to Kiln Indarung II/III and IV in PT Semen Padang. The model is made able to determine the transfer decision on the day-i, workhour-j for Kiln-k optimally. This is evidenced by the model output through Lingo software resulting the total deviation between theoretical and actual fine coal quantity of 6%. This result is much smaller, compared to the conditions at PT Semen Padang before the scheduling model that is equal to 39%. Keywords: Coal Mill, Fine Coal, Integer Linear Programming, Kiln, Model

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