INTRODUCTION

Nama NIK Pendidikan Pengalaman

: Yusup H : 1105111 : S1 Teknik Mesin : Consultan design (2009-2010), Warehouse Staff (2010),

GENERAL PAPERMAKING PROCESS

Plantation

Raw Material

Stock Preparation

Finishing

Paper Machine

RAW MATERIAL
Long fiber :
NBKP ( Needle Bleached Kraft Pulp ) NUKP ( Needle Unbleached Kraft Pulp )

ONP ( Old newspaper )

Recycled paper, which has a content of 60-70% old newspaper, magazine max 30%, other paper & OCC includes 5% max

Short fiber :
LBKP ( Leaves Bleached Kraft Pulp )

BCTMP (Bleached Chemical Thermo Mechanical Pulp )

Short and long fiber

OMG ( Old magazine )

Consisting of old magazine, catalog & similar materials, including other paper & OCC 2%.

Broke ( Recycled Process)

Paper Machine , Finishing , return goods

SWL ( Sorted White Ledger )

office paper

OCC ( Old Corrugated Container )

wrapping paper (box) of food / goods ( brown color )

CACO3 PROCESS

Precipitate d Calcium Carbonate

Ground Calcium Carbonate

CaCO3

1. PCC (Precipitated Calcium Carbonate)

CaCO3 CaO + H2O Ca(OH)2 + Na2CO3

CaO + CO2 Ca(OH)2

CaCO3 + side product

CO2 (NH4)2CO3

Pharmacy, food, milk, mineral water, toothpaste etc

99.8 %

2. GCC (Ground Calcium Carbonate) Size reduction

Dispersant

15-30 cm

<4 cm

<45 m

<2 m

75% solid

Crushing

Dry grinding

Wet grinding

Screening

Storage

CRUSHING
Type:

Jaw crusher

15-30 cm

<4 cm

DRY GRINDING
Rooller Mill (VX Mill)

WET GRINDING
Type:

Atrition Mill
<45 m Dispersant Water

Ceramic bead

Slot screen 0,3 mm

IKSC-95 IKSC-65 IKSF-60

4 stage 2 stage 2 stage

Hardness CaCO3 Ceramic bead

: 4 mohs : 6 mohs

SCREENING
Type :

Vibrating Screen (wire mesh)

Slurry 75% solid

325 mesh 350 mesh

Storage

PRODUCT & STORAGE

IKSC-95 (Indah Kiat Serang Coating -95)

particle <2 m = 95% top side - top coat

IKSC-65 (Indah Kiat Serang Coating -65) particle <2 m = 65% top side - pre coat IKSF-60 (Indah Kiat Serang Filler -60) particle <2 m = 60% (actual : 65%) added in wet end area Duplex (DA) Ivory Capacity : 7,500 ton/month (dry) Filler (top layer) Filler (top layer & back layer)

10,000 ton/month (wet)

Duplex
Top top coat (IKSC-95)
Top pre coat (IKSC-95) Top layer Under layer

Filler layer Back layer

PVA (Poly Vinyl Alcohol)

COLOUR KITCHEN
Film press
Surface sizing

enzyme

Native starch

converter

Jet cooker

COATING
Function: Printability and print quality Paper appearance (gloss, brightness, colour, opacity)

Components of coating process : Base paper Coating colour Coater machine

COATING COLOUR
Pigment The main component of coating color (70-80%), usually mineral particles (CaCO3, Clay 1 & clay 2) Function : filling the pores of the paper surface (smooth) Binder Adhesive used to bond the pigment particles to the base paper( Latex ) Co-binder : Starch & modified starch, PVA & CMC Additives Dispersant, Lubricant, Defoamer, Biocide, Wet strength agent, OBA, Dyes, Caustic soda

COATING COLOUR

Binder & CoBinder

Pigment

Additives

Raw material

Mixing

Screening

Storage tank

Working tank

Coating colour
mixture of pigment + binder + co-binder + additives + water applied to base paper in the coating process

COATING APPLICATION

Working tank

STOCK PREPARATION
131 NBKP 132 LBKP 135 BCTMP 136 BCTMP 140 LBKP 141 BCTMP : 65 T/d : 360 T/d : 350 T/d : 360 T/d : 250 T/d : 250 T/d 134 FILLER I 137 BACK LAYER : 360 T/d : 230 T/d

138 REJECT HANDLING

142 OCC 133 UNDER LAYER

: 60T/d
: 110 T/d : 260 T/d

143 LBKP T PULP: 60 T/d

VIRGIN PULP

WASTE PAPER

VIRGIN PULP
Long Fiber
HD CLEANER DUMP CHEST PULPER REFINER STORAGE TOWER BLENDING CHEST

M/C CHEST

Short Fiber
HD CLEANER DUMP CHEST DEFLAKER REFINER STORAGE TOWER BLENDING CHEST BRUSH REFINER

PULPER

REPULPING

CLEANER

REFINING

BLENDING

REFINING PROCESS
Refining : fibrillation process of fibers or fiber cutting to the degree of freeness (CSF) desired. fiber fibrillation : to improve the physical properties of paper (strength) Fiber cutting : paper formation

SECONDARY FIBER
Under Layer
HD HOLE CLEANER SCREEN

DUMP TOWER
PULPER

SLOT SCREEN

FLOTATION

CLEANER PLANT

THICKENER THICKENER CHEST

DISPERGER

STORAGE TOWER

MIXING CHEST

M/C CHEST

Filler Layer
HD CLEANER
PULPER

M/C CHEST

DUMP TOWER

HOLE SCREEN

CLEANER PLANT

FRACTIONATING

THICKENER
CHEST CHEST

SLOT SCREEN
DISPERGER CHEST

STORAGE TOWER

CHEMICAL & ADDITIVE

1. SIZING Function : To improve the properties of paper (cobb size, penetration, absorption etc) a. Internal Sizing Chemicals directly added to the stock which still form of suspension. Example : ASA b. Surface Sizing Chemicals added to the sheet either still wet or it is dry. Example : Natives Starch addition in the size press 2. DRY/Wet STRENGTH Function : to enhance the properties of paper in a dry time (Ply Bonding, Tensile, Folding etc) Example: Cationic Starch

3. DYES Function : to generate a standard color paper production, measured using a test of L, a, b. Chemical : Basic Dyes ( Blue & Violet)

4. DEINKING CHEMICAL Function : to remove ink on waste paper (brightness will be higher) Chemicals : H2 O2 (Hidrogen Peroxyde), NaOH (soda), Na2 SiO3 (Sodium Silicate), Soap (detergen) 5. COAGULANT & FLOCCULANT Function : Drainage , water purification 6. BIOCIDE Function : to prevent bacterial growth.

PM3/6 PROFILE
Manufacturer
Type Design Speed M/C Width Cylinder Dryer

PM 3

PM 6
Voith Sulzer, Germany

Fourdrinier Multilayer (4 plies) Completed with 4 on line sensor 600 M/Min 4.2 M 87 dryer 2 cooling cylinder

Size Press Coater Rewinder

Jagenberg, Germany 3 coating heads 4 coating heads

Jagenberg, Germany 2,000 M/Min

Duplex (DA,)
Product Triplex (T1) Ivory (IA,)

Ivory (IA, IF, IG, GV)

Art Board (IS,SV)

PAPERMAKING FLOW DIAGRAM

Wire part Press part

Main dryer

Size press

After dryer

Calender 1

Coater 1

Dryer

Coater 2

Coater 3

Calender 2

Cooling cylinder

Pope reel

Stock preparation

Approach flow system

Rewinder

Roll handling

Finished goods

CHEMICALS AND ADDITIVES

Chemical Function

CaCO3

Filler & brightness

ASA Starch

Internal sizing (cobb size)

Flocculant & coagulant

formation and retention

Defoamer

to remove foam

Biocide

to prevent bacterial growth

WIRE PART
Function : 1. Dewatering ( gravity & vacuum drainage) 2. Sheet Formation 3. Ply Bonding (Starch spray)

filler

under

top

back

FORMER & VACUUM SYSTEM

Double side dewatering Very gently and efficient dewatering Highest capacities possible Highest sheet strength, best formation

filler

under

top

back

Filler layer

Under layer

Top layer

Back layer

PRESS PART
Dewatering process by nip press (mechanical drainage) Consist of tri-nip press.

Guide roll

PRESS PART

20 22 % 45 50 %

Stretcher roll

SHOWERING SYSTEM
Use fresh water Oscillating ( HP Shower ) Fix ( LP Shower )

Low Pressure Shower

High Pressure Shower

DRYING
Function : Drying & Evaporating Consist of 87 cylinder dryer (11 Group) and 2 cooling cylinder 6 group ( no 1-69) Main dryer 3 group ( no 70-81) After dryer 1 group ( no 82-83) After coater 1 1 group ( no 84-87) After coater 3

90 95 %

90 95 %

4 80 85 %

STEAM & CONDENSATE SYSTEM

15 bar
Co-GEN 5.5 bar

Coater
Cylinder dryer

Separator
Condensate

SIZE PRESS ( FILM PRESS )

Function : Surface sizing (Starch addition)

CALENDER
Function : 1. Caliper Profiling 2. Sheet Gloss 3. Sheet Density

Hot Oil

HNC

HNC

HNC

SNC

Consist of : Hard Nip Calender Soft Nip Calender

1st

2nd

COATER
Function : 1. Printability & print quality 2. Paper appearance

Drying process : Hot air dryer ( steam 15 bar ) Infra Red dryer

COATING MACHINE CONFIGURATION

Top top coat Top pre - coat Top layer Under layer Filler layer Back layer Back coat

POPE REEL
Production code

C 0 4 30 15
Paper machine identity Year of production Month of production
PM 3 PM 6 :C :D January - September October - December :1-9 : A, B, C

Roll Number Date of production

REWINDER
Winding position

C043015
Core diameter Roll position Number of winding

FINISHING B DEPARTMENT

FINISHING B DEPARTMENT
Tugas : membantu kelancaran proses pemotongan kertas maupun proses pengepakan kertas dari Winder PM B. Finishing B mencakup beberapa bagian : Finishing B Support Section Cutting Section Auto & Manual Packing Section Quality Control

STRUKTUR ORGANISASI FINISHING B DEPARTMENT

Kepala Department Finishing B

Kepala Seksi Finishing B Support Wakil Kepala Seksi Kepala Shift Wakil Kepala Shift Kepala Regu Wakil Kepala Regu Operator

Kepala Seksi Cutting Wakil Kepala Seksi Kepala Shift Wakil Kepala Shift Kepala Regu Wakil Kepala Regu Operator

Kepala Seksi AMPS

QC Finishing Dept.

Wakil Kepala Seksi Kepala Shift Wakil Kepala Shift Kepala Regu Wakil Kepala Regu Operator

Wakil Kepala Seksi Kepala Shift Wakil Kepala Shift Kepala Regu Wakil Kepala Regu Operator

FINISHING B SUPPORT SECTION

SMS : - Menerima Paper Roll dari PM#3 / 6 (Roll in) - Mengatur Roll yang masuk BRSA dan area cutting (Roll out). CCR : Mengeluarkan Roll dari BRSA untuk dipotong di Sheeter atau Winder sesuai memo (PBCR dan PRCR). PCS : Mengontrol order yang belum, sedang atau sudah diproses.

CUTTING SECTION
Tugas :

Memotong Roll yang diproduksi PM #3 dan PM #6 menjadi produk kertas berbentuk sheet / lembaran. Memotong dan menggulung roll-roll dari PM #3 dan #6 untuk menjadi roll yg lebih kecil ukurannya sesuai order dari konsumen.

AUTO & MANUAL PACKING SECTION

Tugas :

Membungkus sheet hasil potongan sheeter dan mengemas sesuai packaging yang diminta costumer Mentransfer Finish Good ke auto warehouse melalui elevator Memotong kertas ke ukuran standar atau sesuai permintaan costumer dengan M/C Polar Memproses Request HB / HF sesuai nota permintaan Suporting: Melakukan reservasi pallet dan material packaging (roll laminating, plastik shrink, strapping PET, lakban, lem, layer)

FLOWCHART ACTIVITY FINISHING B DEPARTMENT

Sheeter Un Sortir Ream Wrapping Manual Wrapping

Sortir BRSA

Semi Auto Wrapping

Paper Roll dari PM #3/6

Shringkage Salvage Winder

Dari Rewinder PM B

Roll Wrapping

Strapping

Auto Warehouse

ROLL RECHEIVING
Roll diterima dari PM3/6 untuk diproses lebih lanjut di Finishing.

ROLL HANDLING

Roll dari PM B distrapping untuk kemudian disimpan di base roll Untuk urgent order, roll di bypass langsung ke cutting area Roll yang order PRCR lewat bypass untuk menyingkat waktu

ROLL HANDLING
Roll yang masuk dalam PBCR, dari slat conveyor dipindahkan ke area cutting dengan travelling kicker oleh operator

 Roll yang tidak masuk dalam PBCR atau PRCR disimpan di Base Roll Storage Area untuk keperluan stock
Base Roll Spesification Capacity Total (A+B) : 15,000 Ton Roll Diameter Roll Width : 1.2 2.1 m : 0.6 2.20 m

BASE ROLL STORAGE AREA

Roll Weight
Roll High/Pile

: 1,000 6,000 Kg
: 0.6 12 m

CUTTING SECTION

SALVAGE WINDER PROCESS

Profil Mesin Salvage Winder Pasaban Jumlah : 2 unit Kapasitas : 50 Ton/Mc/Shift Yue Li Jumlah : 1 unit Kapasitas : 50 Ton/Mc/Shift

GREAT WALL (Barrier Coating) Jumlah : 1 Unit Kapasitas : 30 Ton/Mc/Shift (winding) : 20 Ton/Mc/Shift (barrier coating)

SALVAGE WINDER PASABAN

Pasaban Spesification Maximum winding width Minimum winding width Maximum mother roll diameter Maximum finished roll diameter Finished roll core diameter Number of slitters Minimum sliting width Maximum speed Balancing speed Material to be wound Grammage 2100 mm 600 mm 2100 mm 1500 mm 6 , 10,12 6 200 mm 1500 m/min 1700 m/min Paperboard 250-500 g/m2

SKEMA SALVAGE WINDER PASABAN

Guide Roll Web Roll Unwind

Rider Roll Roll Winding

Core Chuck

Banana Roll Slitter Drum Roll

SALVAGE WINDER YUE LI

Yue lie Spesification Machine Supplier You lie Machinery Paper width 2200 mm Design speed 1500 m/min Basis weight 210-500 g/m2 6,10, 12 Finished roll core diameter Paper quality Board

SKEMA SALVAGE WINDER YUE LI

Roll Unwind Guide Roll

Rider Roll Roll Winding

Core Chuck

Web

Slitter

Drum Roll

SALVAGE WINDER GREAT WALL (BARRIER COATING)

Spesification Paper width 2200 mm Operational speed 800 m/min Basis weight 210-500 g/m2
Finished roll core diameter

Paper quality Chemical kit

6,10, 12 Board Kit 6, kit 8 dan kit 10

SKEMA SALVAGE WINDER GREAT WALL (BARRIER COATING)

Dryer

Rider Roll Roll Winding

Guide Roll

Core Chuck Web

Coater

Roll Unwind Slitter Drum Roll

SALVAGE WINDER PROCESS

SALVAGE WINDER (SW) PROCESS

1. Pasang paper core. 2. Setting Slitter. 3. Pasang paper roll.

QUALITY CHECK

Check kualitas winding Check Size order Roll disusun sesuai order dan label

SALVAGE WINDER PRODUCT AREA

Roll disusun sesuai order,label diletakkan di dalam paper core Pemasangan core plug Pemasangan carton sheet

ROLL WRAPPING PROCESS

MESIN ROLL WRAPPING 1

MESIN ROLL WRAPPING 2

AUTO ROLL WRAPPING PROCESS FLOW

Auto Wrapping Elevator to AW

Winder

Conveyor

Kicker

Labeling

Strapping

Kicker

SEMI AUTO ROLL WRAPPING PROCESS FLOW

Winder Conveyor Kicker Semi Auto Wrapping Conveyor Labeling Strapping Kicker Elevator to AW

SHEETER PROCESS

Sheeter Machine Profile

Old Pasaban Quantity : 6 units Capacity : 42 Ton/Mc/Shift Will Pemco Quantity : 4 units Capacity : 32 Ton/Mc/Shift New Pasaban Quantity : 2 units Capacity : 50 Ton/Mc/Shift Saito Quantity Capacity Tai Yong Quantity Capacity : 2 units : 10 Ton/Mc/Shift

: 1 unit : 5 Ton/Mc/Shift

SKEMA M/C SHEETER

Guide Roll Decurler Nip Roll Slitter Web Banana Roll Roll Unwin d Cross Cutter Outle t Jogger

Overlap

Drum Roll

Fast Belt

Slow Belt

Sheet Stack Pallet

Stacker/ Lay Boy

M/C SHEETER

UNWIND

GUIDE ROLL

DECURLER

NIPP ROLL

TRIM VACUUM

SLITTER

BANANA ROLL

FAST BELT

SLOW BELT

OUTLET

JOGGER

SHEETER OLD PASABAN (2,3,8,9,10 & 11)

Machine Specification :

Machine Width
Maximum Web Width Mother roll dimensions : Maximum roll width Minimum roll width Maximum roll diameter Minimum roll diameter Mother roll core diameter Maximum mechanical speed

: 2300 mm
: 2200 mm : 2300 mm : 430 mm : 2100 mm : 600 mm : 10 & 12 : 300 m/ menit : 300 mm : 1600 mm : 400 mm

Cut sizes:
Minimum slitting width Maximum sheet length Minimum sheet length

Maximum pile height

Maximum knife load at the crosscut Material to be processed Material grammage

: 1600 mm
: 600 GSM : Card board : 250-500 GSM

SHEETER NEW PASABAN (15 & 16)

Machine Specification : Machine width Maximum speed Material to be cut Reel maximum diameter Reel minimum diameter Reel maximum width Reel minimum width Core diameter Maximum length Minimum length Maximum width Stack height (dengan pallet)

: 2300 mm : 320 mm / menit : 175-500 GSM : 2100 mm : 500 mm : 2200 mm : 450 mm : 10 dan 12 : 1600 mm : 350 mm : 2200 mm : 1800 mm

SHEETER WILL PEMCO (4,5,6 DAN 7)

Machine Specification
Machine width Maximum speed Material to be cut Reel maximum diameter Reel minimum diameter Reel maximum width Reel minimum width Core diameter Maximum sheet length Minimum sheet length Maximum sheet width Minimum sheet width Stack height 2300 mm 350 m/min Board 190-400 gr/m2 2100 mm 400 mm 1800 mm 580 mm 6", 10" & 12" 1650 mm 550 mm 1800 mm 410 mm 1350 mm (with pallet)

SHEETER TAI YONG (13 DAN 14)

Machine Specification : Merk Sheeter Cutting Width Minimum Sheet Width Maximum Sheet Length Minimum Sheet Length Unwind Core Diameter Maximum Speed

: Tai Yong : 1600 mm : 400 mm : 1350 mm : 480 mm : 3, 6, 10 dan 12 : 200m/menit

QUALITY CHECK

Quality check oleh QC

team (Visual,Order, Size)

QUALITY CHECK
Macam-macam abnormal sheet: Botak Garis Gelombang Wrinkles Marking Melipat / terjepit GSM campur Kertas basah Calendar mark Coating jelek Bintik hitam Lubang Sobek pinggir

BUFFER AREA (AFTER CUT AREA)

Tempat paper sheet setelah turun dari sheeter dan menunggu proses selanjutnya di AMPS

SORTIR

Sortir dilakukan dengan tujuan untuk mengindari produk (kertas) yang tidak memenuhi spesifikasi (abnormal) terkirim ke costumer

AUTO & MANUAL PACKING SECTION (AMPS)

SHEET WRAPPING PROCESS FLOW

Buffer

Wrapping

Labelling

QC

Shrinking / Stretching

Strapping

QC

AW

PROSES
1. AUTO , SEMI AUTO & MANUAL WRAPPING

Proses pembungkusan Paper Sheet menggunakan Sheet Laminating

2. LABELING Penempelan label pack dan label pallet 3. AUTO & MANUAL SHRINKAGE FILM Proses pengemasan Packing Sheet menggunakan Plastic Shrink 4. AUTO & MANUAL STRAPPING

Proses pengikatan Packing Sheet pada pallet menggunakan Strapping Band

5. HANDED TO AW

Proses transfer produk ke bagian Auto Warehouse

AUTO REAM WRAPPING (WRAPMATIC)

Total Max Speed Ream Paper Substance Max Ream Weight Wrapping Material Substance Glue Type Pallet Size Wide Length Height Production Target : 4500 pack/MC/shif 80 ton/MC/shift Operator outsourching) : 3/shift (2 karyawan + 1 : 5 unit : 15 ream/min : 60 400 gr/m : 40 Kg : Kraft Poly Coated : 80 120 gr/m : Hot Melt : 440 1000 mm : 550 1400 mm : 100 mm

PROCESS FLOW WRAPMATIC

SHEET

REAM FEED GUN

BELT CONVEYOR

LAMINATING PAPER

GLUING (hot melt)

WRAPPING

WOOD PALLET STACKING (slat bar)

CONVEYOR (after wrapping)

SEMI AUTO WRAPPING (AC ROOM)

Khusus costumer dari negara beriklim dingin (Amerika, Jepang) Dikerjakan dalam ruangan tertutup ber-AC Tujuan : Untuk menyesuaikan suhu saat membungkus kertas dengan suhu di negara tersebut (+ 22oC) Untuk mengurangi kontaminasi debu dan kotoran Proses : Secara umum identik dengan auto wrapping Pembungkusannya dilakukan secara manual menggunakan lakban

PROCESS FLOW SEMI AUTO WRAPPING

SHEET

REAM FEED GUN

BELT CONVEYOR

LAMINATING PAPER

WRAPPING (lakban manual)

WOOD PALLET STACKING (slat bar)

LABELING

SHRINGKAGE

STRAPPING

HANDED TO AW

SHEET

REAM FEED GUN

BELT CONVEYOR

LAMINATING PAPER

WRAPPING (lakban manual)

WOOD PALLET STACKING (slat bar)

LABELING

STRAPPING

HANDED TO AW

SEMI AUTO WRAPPING

Maximum Speed Ream Pape Substance Production Target Maximum Ream Weight Total Glue Type Operator Wrapping Material Substance Jenis : Cokelat Putih Savicoat : 5 pack/min : 60 400 gr/m : 2000 pack/MC/shif : 40 kg : 2 unit : Lakban ( ADH Tape) : 3/MC/shift : Kraft Poly Coated : 80 120 gr/m

MANUAL WRAPPING
Khusus produk Ream Wrapping Menggunakan pallet plastik (after sheeter) Pembungkus = kertas laminating Sudah dipotong sesuai ukuran bungkusan sheet 100 cm x 120 cm 120 cm x 150 cm 130 cm x 160 cm 150 cm x 160 cm 75 cm x 140 cm (tambahan / sambungan) Jenis : Cokelat Putih Savicoat Perekat = Lakban plastik (ADH Tape) 100% tenaga manusia (ibu-ibu)

PROCESS FLOW MANUAL WRAPPING

SHEET (AfterCut)

LAMINATING PAPER

WRAPPING (lakban)

WOOD PALLET STACKING (manual)

LABELING

STRAPPING

HANDED TO AW

SHEET (AfterCut)

LAMINATING PAPER

WRAPPING (lakban)

WOOD PALLET STACKING (manual)

LABELING

SHRINGKAGE

STRAPPING

HANDED TO AW

MANUAL WRAPPING
Tenaga : Karyawan Outsourching Target Produksi : Karyawan Outsourching : 2 orang/pasang x 3/shift : 2 orang/pasang x 3/shift : 850 pack/shift : 800 pack/shift

LABELING
Dilakukan setelah proses wrapping Operator menempelkan label Pack & label pallet pada bagian lebar dari pallet Susunan Pack Label harus lurus dari pack atas sampai bawah.

LABELING
Untuk kertas yang belum downgrade, pallet label berukuran kertas A3 & berwarna sesuai dg jenis kertas & jenis packing, diletakkan pada bag.lebar pallet. Pack label di sebelah pinggir kiri sedangkan Pallet label berada di sebelah kanan.

Pack Label

Pallet Label Ukuran A3

 Untuk kertas downgrade, pallet berwarna putih dan berukuran A4, peletakannnya berada di bagian tengah pada bag.lebar dari pallet

LABELING

Pack Label

Pallet Label Ukura n A4

AUTO SHRINKAGE FILM

Mesin :
1. Robopack Senior 2. Octopus Hailola (nonactive) 3. OMS

Bekerja secara otomatis Dilengkapi dengan line konveyor yang terhubung dengan Wrapmatic, Strapping, dan Elevator AW

ROBOPACK SENIOR
Membungkus sheet menggunakan plastik dengan cara dililitkan secara melingkar Material : LDPE 60 m Jumlah lilitan : 3 atas + 2 tengah + 3 bawah Type : Helix system Length : 3810 mm Height : 4235 mm Net Weight : 1700 kg Color : Ral 7030 Arm Rotation Speed : Max 30 rpm Max Capacity : 60 pallet / jam

PROCESS FLOW ROBOPACK SENIOR

CONVEYOR (After Wrapping)

LABELING

CARTON SHEET

ROBOPACK SENIOR (Stretching Fim)

STRAPPING

HANDED TO AW

OCTOPUS HALOILA
Membungkus sheet menggunakan plastik dengan cara dililitkan secara melingkar Memerlukan pemanasan setelah dibungkus Material : LDPE 60 80 m Karena kapasitas terlalu kecil maka mesin tidak digunakan

OMS
Menggantikan fungsi mesin Octopus Haloila Membungkus sheet menggunakan plastik Memerlukan pemanasan setelah dibungkus Material : LDPE 100 m Produksi : 40 pallet/jam Temperatur : 160 210 Celcius Lebar Pallet : 500 1200 mm Panjang Pallet : 580 1400 mm Tinggi Pallet : 1600 mm Stack Weight : 1500 kg

PROCESS FLOW OMS

CONVEYOR (After Wrapping)

LABELING

SHRINGKAGE PROCESS

OVEN

STRAPPING

HANDED TO AW

MANUAL SHRINGKAGE (ROBOPACK JUNIOR)

Batteries Jumlah lilitan

: 12 volt 8 A : 3 atas + 2 tengah + 3 bawah Wheel size : 260 x 70 mm Ukuran stretch film : 50 cm x 30m Kapasitas Maximum : 1 pallet / menit

PROCESS FLOW ROBOPACK JUNIOR

MANUAL WRAPPING

LABELING

SHRINGKAGE PROCESS

STRAPPING

HANDED TO AW

AUTO STRAPPING BAND

Strapping 2 kali : untuk pallet eropa order lokal dan export Strapping 3 kali : untuk pallet asia order lokal, export dan big size Strapping 4 kali : untuk order special packing

Equipment Data: Merk Berat Selling time Strapp feed Tension Strapp width Strapp thickness

: Messersi Packaging : 81 kg : 2 sec : 4 Ms/sec : 200 2400 N : 10 15 mm : 0.4 0.9 mm

POLLAR PROCESS
Alasan utama mengapa produk harus melalui proses polar adalah: HB : Status produk yang sampai di AW tetapi mengalami kerusakan karena penyimpanan/handling, salah transaksi atau salah proses sehingga harus diperbaiki di Finishing. HF : Status produk dimana permintaan Rework berasal dari marketing . Biasanya adalah produk idle stock. Abnormal dari Sheeter

POLLAR PROCESS FLOW

SORTIR RESIZE WITH POLLAR MACHINE SORTIR MANUAL WRAPPING LABELING SHRINGKAGE STRAPPING HANDED TO AW

SORTIR

RESIZE WITH POLLAR MACHINE

SORTIR

LABELING

SHRINGKAGE

STRAPPING

HANDED TO AW

PACKING SHEET DESIGN

Top Heigth = 0.6 cm

TOP

Bottom Heigth = 13.8 cm - 15 cm

ASIAN NONSTOP PALLET

PACKING SHEET DESIGN

Top Heigth = 0.6 cm TOP B O

T
T Bottom Heigth = O 13.8 cm - 15 cm M

EUROPEAN NONSTOP PALLET

REAM WRAPP PACKING A

LOCAL

REAM WRAPP PACKING N DAN M

EXPORT

REAM WRAPP PACKING M BRAZIL

REAM WRAPP PACKING M JEPANG

NON REAM PACKING Q SPECIAL

NON REAM PACKING Q JEPANG

NON REAM PACKING Q BRAZIL

NON REAM PACKING J,K,P

NON REAM PRINTING PACKING R

REAM WRAPP PACKING U UNPALLET

Slip sheet

NON REAM PACKING K

ROLL PALLET DESIGN

Bottom Heigth= 15 cm

PACKING 0

ROLL UN PALLET PACKING 1,2,7,8

ROLL PALLET PACKING 3,4,5,6,9

PROBLEM SOLVING
Less Pack (Pack Kurang)

Solusi : adanya pengecekan jumlah pack oleh QC

Packaging sebelum produk ditransfer ke AW

PROBLEM SOLVING

Strapping miring

Solusi : Pengecekan packing oleh QC Packaging hendaknya lebih teliti

sebelum produk ditransfer ke AW Mechanic/ Electric segera memperbaiki mesin strapping jika hasil strapping tidak sempurna.

TERIMA KASIH

Acknowledge by

Checked by

Presented by

Tsai Cheng Chi

Rul Ngaini

Yusup H