ENHANCING PHYSICAL AVAILABILITY OF PC4000 AT BUMA LATI MINING OPERATION THROUGH MAINTENANCE OPTIMIZATION, SPARE PARTS READYNESS, AND WORKFORCE DEVELOPMENT

Abstract

This study investigates the persistent issue of low physical availability (PA) of PC4000 hydraulic excavators at the BUMA Lati mining operation, which has adversely impacted production performance and revenue. The research identifies key root causes including inadequate maintenance inspection time and quality, limited mechanic competencies, insufficient spare parts readiness, and recurring technical problems—particularly hydraulic and electrical failures. A structured problem-solving methodology, integrating DMAIC and the 3W framework, was employed to develop and implement targeted improvement strategies. These strategies focused on optimizing preventive maintenance processes, improving critical spare parts availability through inventory collaboration, and enhancing workforce capability via competency-based training programs. Post-implementation evaluation revealed an increase in PA performance, reduced downtime, and improvement in customer relationship level (CRL), demonstrating the critical role of coordinated maintenance, supply chain, and human resource interventions in sustaining heavy equipment availability in mining operations.