Improvement of Plant’s Reliability through Web-Based Online Monitoring (Digital Manufacturing Excellence)

PT Pupuk Indonesia (Persero) has 14 total of Ammonia & Urea Plants across Indonesia. Our production facilities are managed by our 5 subsidiaries with total capacity of Ammonia up to 7 million ton per year and up to 9,4 million ton yearly. That big production capacity and high value of asset, it is essential to maintain reliability at high level. High output and reliability of the Plants are crucial because Gas form up to 70% cost of production. If Normal operation of the Plant is disturbed or even cause the plant to be shut down, Cost of Production will go up. The effect on Environment is as much as effect on cost of production. Not to mention global competition in international market, we require a tool to monitor process production thoroughly to keep production high and reliable

Board of Management in production facility and at Holding office, Pupuk Indonesia faces challenges how to monitor and evaluate to prevent shutdown of the Plants. Our team, collaboration among Production department at holding, subsidiaries and IT succeeded to create innovation in order to monitor process production online via website. We call it as Digital Manufacturing Excellence (DMEx).

DMEx is a web based system contains real time operational data send directly from Historian in Distributed Control System in production facilities in our Subsidiaries. This Data then used to monitor process operation real time. It is also utilized to address instability in operation parameter. History of the operational data readily used to address root causes if the breakdown occurs. Furthermore, instable parameter of operation is used as precaution for Plants’ operator to adjust accordingly

This Digitalization has been assisting board of plant’s management from supervisor to Plant manager to monitor plants’ operational and helping board of management in Holding company to take on strategic decisions.