b16. CFT Green One Bu b1 Pati - PT Garudafood PPJ

TEMU KARYA MUTU & PRODUKTIVITAS NASIONAL XX
dan
INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016
"Increase Productivity of Roasted Peanut

by 35% (unit/person) from real
achievement 2014"
UNIT BUSSINESS : BU B1 PATI

PLANT : ROASTED PEANUTS
Project Period : March 2015-November 2015

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COMPANY PROFILE
NAME : PT. GARUDAFOOD PUTRA PUTRI JAYA
LOCATION : PATI, CENTRAL JAVA
PRODUK : ROASTED PEANUTS
ESTABLISH : 1979
PATI
PLANT LAYOUT
CFT PROFILE
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1. INDENTIFY PROJECT THEME
1.1 Define Project Theme
Based on company’s Strategy Map, one of direction from President Letter is to increase
productivity. Therefore our CFT focus on the increasing Productivity.
Recently regional minimum wages

increase by 15% in last three years &
Energy Cost Increase 10%, will impact
significantly to unit cost. So, our CFT
decide to increase Productivity by
decreasing employee cost.
Based on Pareto Unit Cost

2014, Energy & Employee
Cost is the biggest. Contribute
73.33%. Another CFT team is
doing reduction energy cost
project. While, our CFT
handle Employee Cost.
CFT TARGET
TITLE :
Based on data and graph, CFT took the title :
“Increase Productivity of Roasted Peanut by 35%
(unit/person) from real achievement 2014”
CFT Target (500 unit/person) based on average achievement in 2014, that calculate from total unit of finish
goods devided by total finish goods labor (sorting machine up to packaging process, include supporting).
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1.2 Project Scope and Schedule
1.2.1 Project Scope
Information :
CFT Project
covers from
cooking up to
packaging.
1.2.2 Project Schedule
2. IDENTIFY ROOT CAUSE

Information :
CURRENT STATE MAPPING The red marked sentences, are
indentified as non value added process.
This identification as a consideration for
improvement
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2.1 Problem Identification : breakdown the problem-root cause
2.2 Decision Making Analysis for Determining Final Root Cause

-on appendix
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2.3 Verify/Validate Final Root Cause by Data
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3. IDENTIFY IMPROVEMENT PLAN
3.1 Improvement Identification
INFORMATION : choosen
Not choosen
3.2 Analysis Decision Making For Final Solution

- On appendix
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3.3 Risk Assessment process

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3.4 Work Plan
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4. IMPLEMENT IMPROVEMENT
WHAT
NO CFT ISSUE HOW
Before After
1 Disposal of soil and Automation (conveyorization Disposal of soil and filling drying Disposal soil process use conveyor that is directly
filling drying seasoning disposal soil and filling drying) process was manualy connected to upper dump truck and filling the
process were done Where : Cooking & Drying Process drying seasoning process using conveyor connected
manualy When : May 2015 between machines
BEFORE AFTER
INFORMATION : Process that can be eliminated after improvement
Pre cleaning cooking - after
Pre cleaning cooking - before

Disposal soil process use
Disposal of soil process conveyor that is directly connected
was manualy to upper dump truck
Total labor of soil disposal is 14 person/day. Total labor of soil disposal is 4 person/day
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BEFORE AFTER
Drying 1
conveyor
Drying 2 4
Process that can be
INFORMATION : eliminated after
improvement
filling the drying
seasoning process using
conveyor connected
between machine. Time to
filling drying process was filling process takes about
manualy. 31 minutes
Time to filling process takes

about 3 hours 49 minutes
SAVING : Rp. 57,262,400
Drying seasoning
Total labor of drying seasoning process is 4 person/day. Total labor of drying seasoning process is 0 person/day.
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WHAT
NO CFT ISSUE HOW
Before After
2 Design pre-cleaning before the Modification pre cleaning machine by Products are not standard (peanut Gravity Separator proses produces
gravity separator process cannot adding a peanuts roots cutter system still have roots) the manual re- standard products (not peanuts root)
cut the peanut roots optimally Where : process should be done again because peanuts root was cut
Gravity Separator Process maximally
When : August 2015
BEFORE AFTER
Re-process
precleaning can’t cut roots

Stack of sack There is bar in drum
of peanuts optimally
Pre cleaning can cut peanuts roots
Pre cleaning cannot cut optimally. Percent of peanuts roots is
peanuts roots optimally. 0%. So no need to re-process.
Percent of peanuts roots is
0,25%. So manual re-process
should be done again
roots of peanut
Total labor to re-process peanuts roots is 2 person/day Total labor to re-process peanuts roots is 0 person/day
SAVING : Rp. 3,578,900

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INFORMATION ABOUT PRE-CLEANING

5 metres
The shape of precleaning machine of grafity separator is a drum (drum
cleaner). The function is to separate waste from peanuts. To cut roots of
peanuts, the drum are add with peanuts roots cutter system. It modified
80cm with the bar (dia :1 inch, lenght 30cm) into the drum. In every bar, there is bar
holder (dia:1/2 inch, lenght 15 cm), that’s installed cross over with the bar.
There are 4 bar in drum and 3 bar holder in every bar. Way of works :
1. Peanuts that have roots feed into drum
2. Drum is rotating
3. Peanuts will be mixed/rotated and will be hold in the bar holder into
the drum.
4. Roots can be separated from peanuts because of rotation and crash
with bar
WHAT
NO CFT ISSUE HOW
Before After
3 Not balancing Interlock system between need labor to monitor the filing hopper process Installed interlock systems that are connected between
capacity conveyor output drying with gravity separator the input hopper gravity separator with the conveyor
between the hopper gravity separator drying, so the process will stop automatically when the
output of the process in order to balance hopper is full
drying process Where :Gravity Separator
vs hopper Process Total labor to monitor filling hoper process 3 Total labor to monitor filling hoper process 0 person/day
Gravity When : August 2015 person/day
Separator SAVING : Rp. 5,368,350
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BEFORE AFTER
Interlock system Interlock system
There are waste of When hopper is full,

peanuts because sensor on hopper will
operator was too detect and shut down
late to shut down the conveyor
the conveyor. automatically. So, there
That’s makes is no waste of peanuts
peanuts out from and no need labor to
conveyor. monitor process of
filling hopper.
INFORMATION ABOUT INTERLOCK SYSTEM

Step of making interlock system
1. Making wiring diagram (on appendix)
2. Choose the sensor  rotary paddle switch
Way of working interlock system :
1. Unloading drying process. Peanuts transferred by

conveyor and peanuts fill the hopper
2. Sensor is rotating
3. When hopper is full, rotation of rotary paddle will stop
Rotary paddle switch because it is holded by stacked of peanuts in hopper.
Switch sensor in hopper
Specification Rotary Paddle Switch: 4. Sensor will stop conveyor unloading drying
automatically
Model LV 100 220 Vac 50/60 HZ 5. When amount of peanuts in hopper is less, sensor will
Rotary speed 1 Rpm Horizontal rotate and conveyor will run again. Hopper will be
hopper mounting filled by peanut again.
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BEFORE AFTER
Hopper Hopper
There is gap between unloading drying To increase hopper capacity, it’s modified.
with gravity separator capacity about So the hopper can store the product (2.3
Hopper dimension 0.7 ton/hours ton) when unloading drying process
Hopper dimension
WHAT
NO CFT ISSUE HOW
Before After
4 Layout output Relayout gravity Layout output GS process is divided into several The process of storing output machine into 2 locations by
product from separator process by points / locations (4 locations) integrating some multiple conveyor of multiple line
several lines integrating conveyor machines
machine are not output from several Total labor of Total labor of
integrated line machines gravity
Where : gravity separator
separator
Gravity Separator process is 26
Process process is 50
When : June 2015 person/day/2
person/day/2
machine GS
machine GS
SAVING : Rp. 42,946,800

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BEFORE AFTER
INFORMATION : INFORMATION :
4 output locations 2 output locations
STEP of RELAYOUT  goal : reduce output location (to minimize the labors)
Reduce 1st grd output Position before
2nd grd
location : Make 3rd output Reduce 2nd grd
output
- Reverse the direction closer 2nd output output location :
of 2 conveyor output - Move gravity Add 1 conveyor to
1st grade. separator of integrating 2nd
reprocess to Conveyor
- Add 1 conveyor in output, from 2
main gravity output location integrating
front of 2 conveyor
separator become 1 location
output 1st grade due
to integrating 2
1st grd
location become 1 Step 2
Step 1 output Step 3
location
Position after
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WHAT
NO CFT ISSUE HOW
Before After
5 Handling Replacement The use of transport equipment (handpallet) using The use of transport equipment (handpallet) using 3 men labor
products is labor for heavy 2 woman labors (2 labor per handpallet) for 2 Hand pallet (1.5 labor per handpallet)
done by job for Men
women labor
workers Where : Total labor needed
Sorting for feeding
Machine machine is 63
Process,
Roasting Total labor of people (Sorting
Process, dan handling feeding Machine -
Packaging machine is 78 Packaging)
process
people (Sorting
When : May
2015 machine-
packaging) SAVING : Rp. 26,841,750
6 Product is Review Product specification is too bloated among similar Decrease bloated of the product based on the product type and the
very product products that are not injected by nitrogen. Bloated size, because the bloated the higher oxygen content and will shorten
bloated specifications standart is 2,8-3,0 cm shef life. Bloated standart is 2,0-2,5 cm
and there with
is non benchmark Total labor in packaging process is 9 persons/6 Total labor is 8 persons/6 machine (ratio 1.3 person/machine)
value similar machines (ratio of 1.5 people per machine) Total Labor packaging is 72 person/day
added in products Total Labor packaging is 81 person/day
packaging Where :
process Packaging
process SAVING : Rp 16,105,050
When : Sept
2015
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BEFORE AFTER
Review Product Specification Review Product Specification
Bloated of product is decreased (2,0-2,5

Product it’s too bloated (2,8- cm). It’s make operator easier to insert
3,0 cm). Product cannot hold into secondary packaging. Product can
all at once. It’s make difficult hold in one hand. So, packaging time
for operator to insert into can be reduced.
secondary packaging. So, it
Packaging operator get takes long time to
Product can’t hold packaging. Product can hold all at once
difficult to insert into
all at once secondary packaging
Review Dimension Table of packaging Review Dimension Table of packaging
Operator difficult to put on the pallet Reduce lenght of packaging table. Due to
because packaging table is to long. It’s make operator easier to put packaging on
make over motion from operator. the pallet. Lenght of table = 91cm x 49cm
Lenght of tables = 150 cm x 60 cm
Cycle time to packaging Cycle time to packaging

Cycle time can
be reduced 8
second,
because of
review bloated
product &
review
dimension of
packaging table
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WHAT
NO CFT ISSUE HOW
Before After
7 Workload Workload workload supporting worker unequal among the The increased workload of 95-99%, with job enlargement
is not analysis and section, from the average workload of 75% -85%
balance job
enlargement
- Total labor of Supporting is

Total labor of Supporting is 166 person/day 120 person/day SAVING : Rp 82,314,700
ACTIVITY JOB ENLARGEMENT

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WHAT
NO CFT ISSUE HOW
Before After
8 Duplication Review all Duplication works on several activities and 1. Daily, weekly, and monthly reports integrated with one format
works on inspection reports: (pivot table), so that the use of Administrative staff of 13 to 9
several activities and 1. Daily report, weekly, monthly, unintegrated person
activities reports formats and too many amount 2. Decrease inspections frequency based on the number of
inspection Where : 2. Double inspections to every steps of the product defect and inspection was done in the previous stage, are
product and All process process and over frequency not doing again to the next stage, thereby reducing the operator
reports When : May inspection from 58 to 30 person
2015 Total labor for Adminisrative staff and inpection is 39 person
Total labor for Adminisrative staff and inpection is
SAVING : Rp 57,262,400
71 person
BEFORE AFTER
Duplication Reports Duplication Reports
There is 34 - There is 6 reports
types of report (poin 1-6) that
and integrated become
unintegrated one format (using
formats. So it pivot table). So
takes a long administrative staff
time to input just input in one
data by format.
administrative
staff.
- poin 9, confirmation SAP line 2-3
doing per day. So it can reduce report
from 3 become 1 report
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BEFORE AFTER
Duplication quality inspections Duplication quality inspections

There is duplication Eliminate quality inspection
of quality that have same parameter
inspections. (point c, d, f). Also reduce
Especially in frequency of inspections
packaging (product based on evaluation of
ready for packaging) defect (graph of defect trend
and finish goods. on appendix). So it can
reduce inspection labor.
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5. MONITORING & EVALUATION
5.1 Demostrate Capability & Consistency of Performance
Market 64%
Day off only
Iedul Fitri
5.2 Finalize The Result Achievement & CFT Benefit
CONCLUSION : CFT has successfully increased CONCLUSION : Based on Paretto of Cost/Unit ,

productivity by 39.06% (516 unit/org) from CFT After improvement can decrease employee
target 35% ( 500 Unit/Org ) cost by 5.5 billion annualyze
QCDSMP IMPACT
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CFT Benefit
Net Saving /Year is Rp 5.572.797.133,-
FINANCE VALIDATION
Source : FINANCE DEPT
Based on financial validation that calculated by Finance Departement, realization of

employee cost from 2014 to 2015 is decreased. Net saving is Rp. 5,524,442,575,-
This calculation, is not largely different from CFT calculation.
That is Rp. 5,572,797,133,- So, the calculation is VALID.
Employee cost efficiency will give impact to reducing unit cost
TEAM SKILL MAPPING
There is an increasing competency for team after CFT project :

1. Breakdown theme stratification (Didyanto, Sudiyono, Partini, Indah S.)
2. Making improvement plan (Suwardi, Sudiyono, Partini)
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6. STANDARDIZATION
6.1 Standardize The Result & Process
a. Standardization of Result
 Productivity by 516 unit/person
 RESUME labor need/day
 Standardize using men labor to heavy job
b. Standardization of Process
 Work Instruction (WI) Disposal of Soil
No WI-C4.2.0.01-01-05
Content- Disposal soil using conveyorization and dump truck
 Work Instruction (WI) Gravity Separator Process
No WI-C4 2 0 01-01-30
Content Point 4c (Gravity Separator Process)
- Eliminate 2nd grade mixing process manually
 Work Instruction (WI) Seasoning Process
No WI-C4.2.0.01-01-38
Content- Filling drying seasoning machine using conveyor
 Bloated packaging standard
No ST-S1.7.2.00-01-66
Content Bloated Standard GF2 item from 2,8 -3,3 cm to 2,2-2,7 cm
Note : New/revised standard has been socialized (see appendix for attendance list)
6.2 Standardization the machine

- On appendix
7. NEXT IMPROVEMENT PLAN
Based on Pareto Unit Cost 2015, Energy cost is NEXT THEME :

the biggest. Contribute 38.86%. Therefore our "Reduce energy consumption of drying from 0.0091
CFT focus on reducing energy consumption. mmbtu/Kgs to 0.0083 mmbtu/Kgs and 2nd Drying from
0.0021 mmbtu/Kgs to 0.0020 mmbtu/Kgs”
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Step 2.2 Decision Making Analysis for Final Root Cause
Step 3.2 Decision Making Analysis For Final Solution

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Step 4.3 Wiring Diagram Interlock System
Step 4.8 Graph of Defect (defect validation)
Step 6. Standardization of Machine

1. Transportation of disposal soil using dump truck
DUMP TRUCK
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2. Conveyor of Disposal Soil
3. Conveyor transfer drying
4. Conveyor of Output Gravity Separator Process
5. Drum Cleaner with Peanut Roots Cutter System Bar holder
Bar
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Bar
6. Hopper of Gravity Separator
7. Packaging table
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Step 6. Attendance list of document (new/revised) sosialization

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TEMU KARYA MUTU & PRODUKTIVITAS NASIONAL XX

"Increase Productivity of Roasted Peanut

UNIT BUSSINESS : BU B1 PATI

Project Period : March 2015-November 2015

Recently regional minimum wages

Based on Pareto Unit Cost

1.2.2 Project Schedule

2. IDENTIFY ROOT CAUSE

2.1 Problem Identification : breakdown the problem-root cause

2.2 Decision Making Analysis for Determining Final Root Cause

3.2 Analysis Decision Making For Final Solution

3.3 Risk Assessment process

INFORMATION : Process that can be eliminated after improvement

Pre cleaning cooking - after

Pre cleaning cooking - before

Time to filling process takes

precleaning can’t cut roots

SAVING : Rp. 3,578,900

INFORMATION ABOUT PRE-CLEANING

Interlock system Interlock system

There are waste of When hopper is full,

INFORMATION ABOUT INTERLOCK SYSTEM

1. Unloading drying process. Peanuts transferred by

SAVING : Rp. 42,946,800

Review Product Specification Review Product Specification

Bloated of product is decreased (2,0-2,5

Cycle time to packaging Cycle time to packaging

- Total labor of Supporting is

ACTIVITY JOB ENLARGEMENT

Duplication quality inspections Duplication quality inspections

5.2 Finalize The Result Achievement & CFT Benefit

CONCLUSION : CFT has successfully increased CONCLUSION : Based on Paretto of Cost/Unit ,

Net Saving /Year is Rp 5.572.797.133,-

Source : FINANCE DEPT

Based on financial validation that calculated by Finance Departement, realization of

TEAM SKILL MAPPING

There is an increasing competency for team after CFT project :

 Standardize using men labor to heavy job

6.2 Standardization the machine

7. NEXT IMPROVEMENT PLAN

Based on Pareto Unit Cost 2015, Energy cost is NEXT THEME :

Step 2.2 Decision Making Analysis for Final Root Cause

Step 3.2 Decision Making Analysis For Final Solution

Step 4.8 Graph of Defect (defect validation)

Step 6. Standardization of Machine

3. Conveyor transfer drying

4. Conveyor of Output Gravity Separator Process

5. Drum Cleaner with Peanut Roots Cutter System Bar holder

6. Hopper of Gravity Separator

Step 6. Attendance list of document (new/revised) sosialization

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