Project time linemupstream

NO Project Januari februari Maret

1 Fat liqour control

2 Line C and A/B RF bypass Rifiner stage 3 and 4 Line A/B

Bottlenecking project (Increase Roasting batch

line AB/ capacity from 850 kg to 1000 kg and line Line B1
C 2700 - 3000 kg)
3
Potentially to be implemented
4 Using 50 % Solution on alkalizer Done
when we have good result

5 Shell in nib control

6 Potensial project *

* There some potensial project that we can held, like L value project, energi project, but we need to brainstrorming firs
 April mei juni juli Agustus september
monitoring
Line C monitoring

Line B2 Line A1 Line A2 Line C Monitoring

Potentially to be implemented
Monitoring
when we have good result
monitoring

gi project, but we need to brainstrorming first we other side

Project background :

To maintance Fat after press on our spech (10-12%) press need to control some parameter, one of them
are Liqour fat

Objective
1. To maintance liqour fat not more than 54 %

Phase
Date Milestone
1 Look the data and prioritas the analysis
2 define the problem and develop project charter
3 map the process and validate the data
4 Root causes analysis
5 Define and implementation action plan
1. fat monitoring form
2. PG 02 and 01 automatict valve censory connect to ampere PG
3. Stair for PG 07
4. Replace butter valve with proper one
PG 01
PG 05
5. Replace butter valve with the scale valve (long term, need budget around $ 1000)
6 Sustain the solution

BEFORE INITIATIVE

LT Press November
Normal
90 88 Mean 53.40
84
StDev 1.147
80 N 799

70 67
61
59
60 55
Frequency

50 49
50
44
40
40 36 37
33
30
30

20
14

10 8
5 6 6 7 6
3 4
1 0 2 2 2
0 0 0 0 0 0
0
0 0 50 0 0 5 50
.0 .0 . .0 .0 .2 .
51 52 52 54 55 56 57

nov press

AFTER INITIATIVE

LT Press Januari
Normal
79 Mean 53.88
80
74 StDev 1.261
 LT Press Januari
Normal
79 Mean 53.88
80
74 StDev 1.261
N 734
70
63
61
60 56

50
50
Frequency

45
43

40 36
35

30 28

22 21
19
20 16 16
13 14 14
11
10 7
3 4
2 2
0 0 0
0
51 52 53 54 55 56 57 58
jan

Root cause analysis

1. automatic valve buter for PG 01 and 02 did not have sistem to auto off their supply butter when supply material fo
suplly do to waiting nib in roasting procces) its cause butter will still supply to PG even nib are not there. butter will tr
and cause high fat condition. in current condition we only depends on labor control to manual off Butter supply to av
2. valve butter not proper, there is no opening scale on this valve, so we cannot measure how much this valve open.
3. Dicipline to adjust out fat
4. sample fat that sending to QA to analysis need time to process.

5. PG 07 valve butter possition are difficult to rearch, the stair that we have cannot acces to valve butter do to narrow
n our spech (10-12%) press need to control some parameter, one of them

more than 54 %

Milestone PIC date

ioritas the analysis fauzi done
and develop project charter fauzi done
d validate the data fauzi done
fauzi done
ntation action plan fauzi done
fauzi done
matict valve censory connect to ampere PG Bresly Mar-20
Bresly Mar-20
ve with proper one Bresly
Bresly done
Bresly 28 februari 2020
ve with the scale valve (long term, need budget around $ 1000) TBC
fauzi Apr-20

LT Press November LT Press de

Normal Normal
88 Mean 53.40 80
84 74
StDev 1.147
N 799
70
63
67
60 58
61 55
5 51
49 50
45 4
Frequency

44
41
36 37 40
30
30 27
24
20
20 17
8
6 7 6 12
4
2 2 2 10 9 10
0 0 0 0 0 0
10 7
0 0 5 50 2
.0 .0 .2 . 0 0
54 55 56 57 0
50.0 51.2 52.0 52.8 53.6 54
nov press
des press

LT Press Januari LT Press Febru

Normal Normal
79 Mean 53.88 50
47
74 StDev 1.261
 LT Press Januari LT Press Febru
Normal Normal
79 Mean 53.88 50
47
74 StDev 1.261
N 734
40
63 40
35
56 34

30
30

Frequency
43 26
24
36

20 18
28
15
22 21
19
16 10 10
14 14 10
11 6

4 2 2
2 2
0 0 0
0
3 54 55 56 57 58 50.4 51.3 52.0 52.5 53.1 54
jan press feb

01 and 02 did not have sistem to auto off their supply butter when supply material form roster empty (discontinue
ting procces) its cause butter will still supply to PG even nib are not there. butter will trough to IT and continoue to LT
current condition we only depends on labor control to manual off Butter supply to avoid that situation
e is no opening scale on this valve, so we cannot measure how much this valve open.

A to analysis need time to process.

are difficult to rearch, the stair that we have cannot acces to valve butter do to narrow acces (PG 07)
 LT Press des
Normal
Mean 53.35
74
StDev 1.114
N 749

63
58
55
51
47
45 44
41

30
7
24 25
20 20
18

12 11
10
7
4 4
2
0

52.0 52.8 53.6 54.0 54.5 55.2 56.0

des press

LT Press Februari
Normal

47 Mean 52.75
StDev 1.303
 LT Press Februari
Normal

47 Mean 52.75
StDev 1.303
N 350
40

35
34

30

26
24

16

0
9
7
6 6
5
2
0 0

52.0 52.5 53.1 54.0 54.9 55.8

press feb
Project background :

ACM can work at product finenes 98.5 %, but now we feed ACM with finenes around 90
%, in other side press also working more efective in product finenes 98.5

Objective
1. To maintance liqour finenes to acm aroud 98.5 %
2. Make RF process more eficien with only using 2 RF from 3 RF

Phase
Date Milestone
1 Look the data and prioritas the analysis
3 map the process and validate the data
4 Potensial saving
5 Define and implementation
by pass line A/B
by pass line C
6 Sustain the solution

Potensial saving from by pass RF stagre 3 Rf line A and C

Line A Bypass 3rd stage refiner

Line C Bypass 3rd stage refiner

Electricity Consumption
Refiner Flow Rate 99.5 Flow Rate 98.5
Power (kW)
Motor (Ton/Hour) (Ton/Hour)
RF05 55 2 2
RF06 55 2 2
RF07 55 2 2
RF12 55 2 2
RF13 55 2 2
RF14 55 2 2

Electricity
Electricity Component Price
WBP Hours LWBP Hours Price IDR / KWH
IDR / KWH
LWBP 1,036 21
1,229.85
WBP 1,553 5

USD to IDR Exchange Rate 14,114.29

Refiners KWH Requirement

Line Liq 99.5% Liq 98.5% Delta KWH
Line A 3,366 2,244 1,122
Line C 3,366 2,244 1,122

Electricty Saving / A day in USD

Line A $ 97.77
Line C $ 97.77

Total
Potential $ 195.53
Saving

Electricty Saving / A month

$ 5,865.93 82,793,445.90

Electricty Saving / A year

$ 70,391.17 993,521,350.80
 PIC date
fauzi done
fauzi done
fauzi done
fauzi done
Bresly 12-Mar-20
Bresly Apr-20
fauzi Apr-20

55
Project background :
To increase bottle neck from roaster

Our Current process capacity

Objective
1. To increase Line AB capacity from 0.85 ton/batch to 1 ton/batch

Phase
Date Milestone PIC date
1 Look the data and prioritas the analysis Gaurov done
3 Map the process and validate the data Fauzi done
4 Define and implementation fauzi done
line b1 (850 -1000 kg) gradualy 50 kg fauzi/ Bresly Mar-20
line b2 (850 -1000 kg) gradualy 50 kg fauzi/ Bresly Apr-20
line b3 (850 -1000 kg) gradualy 50 kg fauzi/ Bresly May-20
line b4 (850 -1000 kg) gradualy 50 kg fauzi/ Bresly Jun-20
Line C (2700 - 3000 kg) gradually fauzi/ Bresly Jul-20
5 Sustain the solution fauzi Aug-20
Project background :

In November & December we found that some

winnower produce nib with sin > 1.75

Objective
1. To maintance SIN below 1.75 %

Phase
Date Milestone PIC date
1 Look the data and prioritas the analysis fauzi/ Ricky done
2 define the problem and develop project chafauzi/ Ricky done
3 map the process and validate the data fauzi/ Ricky done
4 Root causes analysis fauzi/ Ricky done
5 Define and implementation action plan fauzi/ Ricky done
1. Conduct trining to operator fauzi/ Ricky done
2. Maintanance winnower no2&3 Bresly On progress
3. Suction win 3 & 4 Bresly On progress
4. Visual SIN control fauzi Done
6 Sustain the solution

Process Performance
BEFORE INITIATIVE

November SIN
2.9
W1 C

2.7 W4 C

2.5

2.3

2.1 W3 E W3 E
W3 F
W4 C
W3 E W3 F W6 s
W3 E W3 E W3 A
1.9

1.7

1.5

1.3
1 7 13 19 25 31 37 43 49 55 61 67 73 79 85 91 97 103109115 121127 133139 145151157163169 175181 187193

Sin Standard
AFTER INITIATIVE

1.8 Januari SIN

1.75

1.7

1.65

1.6
SIN

1.55

1.5

1.45

1.4
1 10 19 28 37 46 55 64 73 82 91 100 109 118 127 136 145 154 163 172 181 190 199 208 217 226 235 244 253
SIN
 December SIN
2.8 W6 S

2.6

2.4
W4 Cm
2.2

W1 Cm
2
W1 Cm W4 E
W4 EW1 Cs
1.8

1.6

1.4
1 10 19 28 37 46 55 64 73 82 91 100109118127136145154163172181190199208217226235244253
51157163169 175181 187193

Sin standard
 Februari SIN
1.8

1.75

1.7

1.65

1.6

1.55

1.5

1.45

1.4
08 217 226 235 244 253 1 7 13 19 25 31 37 43 49 55 61 67 73 79 85 91 97 103 109 115 121 127 133 139 145 151 157 163 169

Sin standard
9208217226235244253
7 133 139 145 151 157 163 169