The sound of lathe machines, welding activity, hydraulic system\ninspections and component testing form part of daily life for workers at\nthe Cirebon Prujakan Mechanical Workshop. At the facility, various rail\ntrack maintenance machines are inspected and serviced before returning\nto KAI\u2019s operational areas across the island of Java.<\/p>\n
The Cirebon Prujakan Mechanical Workshop is PT Kereta Api Indonesia\n(Persero)\u2019s main maintenance facility, located at Jalan Kesambi Number\n2, Cirebon City, West Java, close to Cirebon Prujakan Station.<\/p>\n
The facility handles periodic maintenance, heavy maintenance,\nrepairs, function testing and technical capability adjustments of Rail\nTrack Maintenance Machines. In KAI\u2019s technical asset records, these\nmachines are also known as Rail Track Maintenance Trains (KPJR).<\/p>\n
KAI Vice President Corporate Communication Anne Purba said the work\nat the Cirebon Prujakan Mechanical Workshop is closely linked to route\nreadiness and the safety of train journeys.<\/p>\n
\u201cSafe train journeys require stable track conditions that meet\ntechnical standards. Track maintenance machines help maintain these\nconditions. Therefore, every machine must be verified as reliable before\nreturning to the lines,\u201d said Anne.<\/p>\n
Track maintenance machines assist with lifting and aligning track,\nadjusting rail height, compacting ballast, shaping the ballast profile,\nand stabilising the track after maintenance work.<\/p>\n
Ballast is an arrangement of crushed stone placed beneath and around\nrail sleepers. This material helps support the sleepers, distribute the\nload of train journeys, maintain track stability and facilitate water\ndrainage around the rails.<\/p>\n
When the track position or ballast density changes due to traffic\nloads and environmental conditions, maintenance machines are used to\nrestore the track geometry to technical requirements. Track geometry\nencompasses alignment, elevation, gauge distance and track gradient.<\/p>\n
In 2026, the Cirebon Prujakan Mechanical Workshop has a maintenance\nprogramme covering 51 track maintenance machines. As of 17 July 2026, 22\nunits, or 43.1 per cent, had completed maintenance, with seven units in\nprocess. A further 22 units are scheduled for the next phase of\nmaintenance.<\/p>\n
Generally, the MTT, or Multiple Tie Tamper, is used to lift, align\nand compact the track. The PBR, or Plasser Ballast Regulator, is used to\narrange and shape the ballast profile around the sleepers.<\/p>\n
A turnout (wesel) is a rail track structure that allows trains to\nmove from one track to another. The positional accuracy of turnout\ncomponents must be maintained as it relates to the direction of train\ntravel.<\/p>\n
\u201cEach machine has a different function. Some machines correct rail\nposition, compact ballast, arrange material around sleepers, and assist\nwith work on turnouts. All these functions support one another so that\nthe track remains safe for trains to pass,\u201d said Anne.<\/p>\n
The machines serviced at Cirebon Prujakan support the needs of\nOperational Region (Daop) 1 Jakarta, Daop 2 Bandung, Daop 3 Cirebon,\nDaop 4 Semarang, Daop 5 Purwokerto, Daop 6 Yogyakarta, Daop 7 Madiun,\nDaop 8 Surabaya and Daop 9 Jember.<\/p>\n
This coverage makes the Cirebon Prujakan Mechanical Workshop one of\nthe main supporters of KAI\u2019s infrastructure maintenance across the whole\nof Java. Once maintenance and testing are complete, machines can return\nto service according to the needs of each operational region.<\/p>\n
According to performance data, the Cirebon Prujakan Mechanical\nWorkshop completed 50 machine maintenance jobs in 2024 and 53 jobs in\n2025. As of 17 July 2026, 22 jobs had been completed. Overall, there\nhave been 125 completed maintenance jobs from 2024 to mid-July 2026.<\/p>\n
The work uses P12, P24 and P48 maintenance patterns with their\nrespective phases. P12 is maintenance on a 12-month cycle, P24 is\ncarried out every two years, while P48 is conducted every four years\nwith a broader scope of inspection.<\/p>\n
The maintenance process covers inspection of mechanical, hydraulic,\nelectrical, braking, propulsion and machine working systems. The scope\nof work is determined by each machine\u2019s type, age, working hours,\ncomponent condition and fault history.<\/p>\n
The machines serviced range in production years from 1984 to 2024.\nSome 23 units date from the 1984\u20131994 period, eight units from\n2013\u20132015, and 20 units from 2020\u20132024.<\/p>\n
This diversity of ages and technologies requires workers who\nunderstand mechanical systems from various generations. Older machines\ndemand precision in component inspection and spare part adjustment,\nwhile newer-generation machines are equipped with more complex control\nsystems and electronic devices.<\/p>\n
As of 1 May 2026, the Cirebon Prujakan Mechanical Workshop is\nsupported by 48 workers, comprising 21 permanent employees, 20\noutsourced maintenance personnel, three cleaning staff and four security\npersonnel.<\/p>\n
The workers handle tasks ranging from maintenance programme planning,\ncomponent disassembly, damage inspection, repair, reassembly and\nfunction testing, through to quality control of the finished work.<\/p>\n
A Service Level Agreement assessment of the 20 outsourced maintenance\npersonnel in April 2026 recorded an average score of 96.6. This score\nreflects work performance based on quality, discipline, safety and\nachievement of established targets.<\/p>\n
Workers\u2019 competencies are strengthened through certification and\ntraining in general occupational health and safety (K3), chemical\nsafety, first aid, fire suppression, wastewater management, and\nhazardous and toxic waste management.<\/p>\n
The workshop also has workers certified in overhead crane, forklift\nand lifting jack operation, as well as technicians for lifting and\ntransporting equipment, and power and production machinery.<\/p>\n
\u201cMachine reliability depends heavily on workers\u2019 precision and\ncompetence. Every stage must be carried out according to procedure, from\ninitial inspection, component repair and installation, through to\ntesting before a machine is declared ready for use,\u201d said Anne.<\/p>\n
To support this work, the Cirebon Prujakan Mechanical Workshop is\nequipped with overhead cranes, lathes, milling machines, forklifts,\ncutting machines, hydraulic presses, lifting jacks, hand lifts,\ngenerators, nitrogen accumulator filling machines, scissor lifts and\nhigh-pressure washers.<\/p>\n
This equipment helps workers lift large components, shape materials,\nrepair parts, clean machine devices and carry out work on both upper and\nlower sections of the equipment.<\/p>\n
The Cirebon Prujakan Mechanical Workshop implements the ISO 9001:2015\nQuality Management System and the ISO 14001:2015 Environmental\nManagement System. Environmental management is carried out through\nwastewater treatment installations, hazardous and toxic waste\nmanagement, tree planting, garden revitalisation and hydroponics.<\/p>\n
Control standard data up to April 2026 recorded zero work accidents,\nzero environmental pollution and zero delays in the maintenance\nprocess.<\/p>\n
\u201cJourney safety is built from a great deal of work behind the scenes.\nTrack readiness in the field, the reliability of maintenance machines,\nworker competence and discipline in every process are interconnected\nelements that keep train journeys safe across Java,\u201d Anne concluded.<\/p>", "url": "https:\/\/jawawa.id\/newsitem\/cirebon-prujakan-mechanical-workshop-maintains-reliability-of-51-rail-maintenance-machines-for-all-of-java-1784357547", "image": "" }, "sponsor": "Okusi Associates", "sponsor_url": "https:\/\/okusiassociates.com" }