This study addresses the critical need to enhance the efficiency and productivity of cement production in Banda Aceh and North Sumatra, regions identified as sold-out markets for cement. Given the high demand in these areas, maintaining optimal plant availability and performance is essential. The focus is on improving the production rate (PRI), reducing thermal energy consumption (STEC), and ensuring efficient electrical consumption (SEEC), all while guaranteeing that the cement quality meets SNI standards. The primary objective is to reduce SEEC by 2 kWh per ton of cement and to increase the production rate by 10-15 tons per hour (TPH). To achieve these goals, the study implements strategic maintenance and optimization measures, such as cleaning diaphragm slots and adding grinding balls in the first and second chambers of the cement mill. These interventions are designed to enhance grinding efficiency by reducing blockages and improving material flow. The data were collected through forum group discussions (FGD) and questionnaires, with insights analyzed using fishbone diagrams to identify root causes and SWOT analysis to evaluate the strengths, weaknesses, opportunities, and threats of the proposed changes. The addition of grinding balls increases impact and attrition forces, resulting in finer grinding of raw materials. These combined measures contribute to lower energy consumption and higher production rates, ensuring that the plant operates efficiently without compromising cement quality. The study highlights the importance of regular maintenance and strategic upgrades in achieving operational excellence and sustainability, especially in high-demand markets like Banda Aceh and North Sumatra, where consistent plant performance is crucial to meeting market needs.
Aziz et al. (Wed,) studied this question.