01
Challenge
The client was moving 38 production machines from Tangerang to a new plant in Karawang. Management would accept no more than one week of downtime.
Machines had to arrive in installation order, because the foundations at the new plant were prepared line by line.
- 210 tonnes in totalThe heaviest machine weighed 14 tonnes and needed a forklift and crane at both sites.
- Line-by-line orderOne machine out of sequence would hold up a whole line.
- Truck curfewsHeavy trucks are restricted on the Jakarta–Cikampek toll road at peak hours.
02
Solution
-
1
Dismantling sequence mapped
Machines were grouped by production line and scheduled day by day.
-
2
Fuso and tronton trucks in rotation
Fuso trucks for lighter machines, tronton trucks for heavy ones, all outside curfew hours.
-
3
Rigging crews at both sites
One crew dismantled in Tangerang while another placed machines in Karawang the same day.
-
4
Line-by-line handover
Each line was checked with the client's technicians before the next one was dismantled.
03
Results
- days to move 38 machines, against an 8-day target
- 6
- machines damaged in transit
- 0
- days ahead of plan
- 2
Signed handover reports for every line and before-and-after condition photos are available for review.
Project photos
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Loading at the original plant. -
PHOTO: tronton truck carrying a heavy machine on the toll road at night
Travelling outside curfew hours. -
PHOTO: rigging crew lowering a machine in Karawang
Unloading at the new plant. -
PHOTO: client technician checking a machine on its new foundation
Line-by-line handover.
“The machines arrived in exactly the order we asked for, so our technicians never had to wait. The first line was running on day three.”