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    Automatic Powder Transfer System: 15 Januari 2016

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    Haris Prawoto
    The document discusses an engineering services proposal for an automatic powder transfer system. It proposes upgrading from a manual system with 17 operators to an automated system requiring only 3 operators. This would optimize manning by reducing operators from 17 to 3, saving an estimated 336 million rupiah per year in labor costs. The automated system would also significantly reduce processing and handling times, increasing production capacity and potential profit from additional sales. It estimates a total potential savings of 837 million rupiah annually from reduced costs and increased sales. With a proposed investment of 3.356 billion rupiah, the automated powder transfer system would achieve a return on investment within 4 years.

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    Automatic Powder Transfer System: 15 Januari 2016

    Uploaded by

    Haris Prawoto
    48 views13 pages
    The document discusses an engineering services proposal for an automatic powder transfer system. It proposes upgrading from a manual system with 17 operators to an automated system requiring only 3 operators. This would optimize manning by reducing operators from 17 to 3, saving an estimated 336 million rupiah per year in labor costs. The automated system would also significantly reduce processing and handling times, increasing production capacity and potential profit from additional sales. It estimates a total potential savings of 837 million rupiah annually from reduced costs and increased sales. With a proposed investment of 3.356 billion rupiah, the automated powder transfer system would achieve a return on investment within 4 years.

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    Packaging system

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    The document discusses an engineering services proposal for an automatic powder transfer system. It proposes upgrading from a manual system with 17 operators to an automated system requiring only 3 operators. This would optimize manning by reducing operators from 17 to 3, saving an estimated 336 million rupiah per year in labor costs. The automated system would also significantly reduce processing and handling times, increasing production capacity and potential profit from additional sales. It estimates a total potential savings of 837 million rupiah annually from reduced costs and increased sales. With a proposed investment of 3.356 billion rupiah, the automated powder transfer system would achieve a return on investment within 4 years.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    48 views13 pages

    Automatic Powder Transfer System: 15 Januari 2016

    Uploaded by

    Haris Prawoto
    The document discusses an engineering services proposal for an automatic powder transfer system. It proposes upgrading from a manual system with 17 operators to an automated system requiring only 3 operators. This would optimize manning by reducing operators from 17 to 3, saving an estimated 336 million rupiah per year in labor costs. The automated system would also significantly reduce processing and handling times, increasing production capacity and potential profit from additional sales. It estimates a total potential savings of 837 million rupiah annually from reduced costs and increased sales. With a proposed investment of 3.356 billion rupiah, the automated powder transfer system would achieve a return on investment within 4 years.

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    Engineering Services

    AUTOMATIC POWDER TRANSFER SYSTEM


    15 Januari 2016
    DATA PRODUKSI

    LINE
    MC.1 MC.2 MC.3 MC.4 MC.5 MC.6 MC.7 MC.8 MC.9 MC.10 MC 11
    PRODUK MC 10 A MC 10 A MC 10 A MC 10 A MC 10 A MC 10 A MC 10 A MC 50 A MC 50 B MC 50 C MC 50 E
    BOBOT 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 20 gr/sct 47 47 47
    1
    KAP/JAM
    (kg/jam) 11,04 11,04 11,04 11,04 11,04 11,04 11,04 360 112,8 112,8 112,8

    A B C D
    CC 25/ES CC 25/ES
    PRODUK CC 50 CC 50 CC 50 CC 50 25 25 TOTAL
    BOBOT
    2
    (gr/sct) 40 40 40 40 20 20

    KAP/JAM
    (kg/jam) 96 96 96 96 48 48 480

    KAPASITAS PER JAM 1255,68 KG


    KAPASITAS PER SHIFT 10.045,44 KG
    KAPASITAS PER BULAN 251.136,00 KG
    SAAT INI

    Total 17 operator / manning

    Sacharin
    (Powder)
    5%
    V Mixer
    Manual T8ipping
    Na-Cyclamat
    (Powder)
    95% Zak to machine
    Filling Sachet
    hopper chute

    Fill to ZAK-Packing

    Lift Manually
    Put Zak on the
    With overhead
    Pallet
    crane

    MIXER 2
    USULAN SYSTEM

    Total 3 operator / manning

    Sacharin
    (Powder)
    5%
    Storage RM , Auto
    V Mixer
    dosingT8ipping
    Manual ke Mixer
    Na-Cyclamat
    (Powder)
    95% Zak to machine
    Filling Sachet
    hopper FG
    Transfer chute
    dari
    storage FG Tank
    Fill to ZAK-Packing
    ke Filling Hopper
    Storage MIXED
    Finished Good
    (FG)
    Put Zak on the
    Lift Manually
    With overhead
    Pallet
    crane
    LAYOUT SYSTEM
    LAYOUT SYSTEM
    TIPPING TIPPING
    Capacity 1 TON Capacity 1 TON
    Volume 1,5 TON Volume 1,5 TON

    90% 10%
    WEIGHER RM 1 12-30bpm 15 L x 2 WEIGHER RM 2 12-30bpm 15 L x 2
    Capacity min 180 kg/min Capacity min 180 kg/min
    Capacity max 450 kg/min Capacity max 450 kg/min
    clean process for 1 ton 900 kg/batch clean process for 1 ton 100 kg/batch
    5,0 min/batch 0,56 min/batch
    2,0 min/batch 0,22 min/batch

    MAIN MIXER
    Capacity 1 ton/batch
    clean process 1 min - fitting pos
    5,0 min - weighing RM
    10 min - mixing
    1 min - fitting pos
    2 min - discharge
    19 min - total / 1ton batch

    FG HOPPER - 1 FG HOPPER - 2
    775,68 kg/hr 480 kg/hr
    6,21 ton/shift 3,84 ton/shift

    133 min / 7 ton 133 min / 7 ton


    2,22 hr / 7 ton 2,22 hr / 7 ton

    CLEAN VOL 8 ton CLEAN VOL 8 ton


    CAP FOR 1 SHIFT CAP FOR 2 SHIFT VACUUM HOPPER - 1 VACUUM HOPPER - 2
    775,68 kg/hr 480 kg/hr
    12,93 kg/min 8,00 kg/min
    hopper 1 ton hopper 1 ton
    vol 1,5 ton vol 1,5 ton

    low level 0,5 ton low level 0,5 ton


    vacum 100 kg/min vacum 100 kg/min
    compare VFFS 7,7 x req compare VFFS 12,5 x req

    Total 11 VFFS machine Total 6 VFFS machine


    BENEFIT TANGIBLE

    Optimalisasi jumlah manning operator


    • Total 17 orang  3 orang optimalisasi 14 orang
    • 14 x 2j/bln x 1 shift x 12 bln  336 jt / tahun

    Mengurangi proses dan waktu handling secara signifikan


    1 batch 110kg menjadi 1 ton / batch
    • Total 1 shift capacity yang dibutuhkan : 10 ton / shift
    • Waktu mixing total 1 shift :
    • Current : 110 kg  10 menit 55 detik  11 menit
    10 ton  1000 menit  16,7 jam

    • System Auto : 1 ton  19 menit untuk perhitungan menjadi 20 menit maximal


    10 ton  200 menit  3,3 jam

    • Saving time : 800 menit  13,3 jam

    • Potential production loss 13,3 jam :


    • Kapasitas 1 jam : 1255,68 kg/jam
    • Hilang kapasitas 13,3 jam : 16,7 ton product
    • Estimasi, harga product per ton : Rp 100jt / ton
    • Estimasi profit margin sales per ton : 30%
    • Potensial profit loss : Rp 100jt x 30% x 16,7 ton = 501 jt/ tahun
    BENEFIT INTANGIBLE

    Simplifikasi flow RM FGM PM


    • Semua proses flow powder dari RM sd FGM di dalam system, tidak ada yang di luar system

    Stock control RM dan FGM lebih baik / lebih mudah


    • Storage di tanki yang terpantau volume isi nya dengan mudah

    Meningkatkan hygiene product handling


    • Product handling menggunakan SUS 304 food grade

    Mengurangi jumlah product waste dengan system penimbangan yang akurat


    • System batching dilakukan dengan penimbangan secara akurat untuk mendapatkan hasil
    masksimal sesuai recipe
    PERHITUNGAN ROI

    Total Tangible Saving


    • Manning saving 336 jt / tahun
    • Potential sales margin loss 501 jt / tahun
    • TOTAL 837 jt / tahun

    ROI
    • Investasi total 3,356 M
    • ROI : 3,356 / 0,837 = 4 tahun
    PROJECT EXPERIENCES

    • PT. NESTLE INDONESIA CIKUPA ( Relay out & installation new


    machine, retrofit, conveyor system , electrical & control system
    support, application new machine can & filling , making new can
    machine.

    • PT. INDOLAKTO JAKARTA PLANT (Vacuum transportation system,


    retrofit filling, plumbing  process , relay out & civil
    contractor)

    • PT. INDOLAKTO PANDAAN PLANT ( Application new machine trident


    pack cartoner, Application & supply leak detector Taptone )

    • PT. INDOLAKTO PURWOSARI PLANT ( Application & supply leak


    detector Tap tone, Making Crusher waste machine, conveyor
    curving & tipping )

    • PT. KRAFT FOODS INDONESIA CIKARANG PLANT ( Wide hygiene


    conveyor, carton sealer new application )

    • PT. MONDELES INT. KARAWANG PLANT ( Wide hygiene conveyor, carton


    sealer new application, pilot plant miniature making)
    • PT. INDOFOOD SUKSES MANDIRI ( Retorfit Sachet Filling Machine )
    • PT. SARIHUSADA ( Erection & Installation New Machine Filling
    Packing, Retrofit / refurbishment, mechanical, electrical &
    control system support, spare part supply  for filling & packing
    machine, customize spare part order or making order
    • PT. NUTRICIA INDONESIA SEJAHTERA ( conveying system, Retrofit
    Filling machine )
    • PT. ICI PAINT INDONESIA AKZO NOBEL ( Consultant  Project for
    Packaging )
    • PT. DANONE DAIRY INDONESIA ( Consultant Project )
    • PT. JOHNSON&JOHNSON INDONESIA ( Consultant Project )
    • PT. DAIRY GOLD INDONESIA ( Conslutant Project )
    • PT. ULTRA JAYA ( Hygienic Conveying System Project)
    • PT. SCIENTIFIC DRILLING INTERNATIONAL  ( Consultant Project )
    • PT. PRIMA MAKMUR ROTOKEMINDO  ( Partition Project )
    • PT. UNILEVER Food ( Walls ) Cikarang ( Conveying System Project) 
    • PT. UNILEVER SARIWANGI Cicadas ( Retrofit machine, supply new
    shrink tunnel  )
    • PT. PZ CUSSON TANGERANG ( Supply inline machine linear filling
    machine, conveying system machine )
    • PT. ARNOTTS INDONESIA ( Conveying system, new machine
    installation, plumbing process project,  vacuum leak tester )
    • PT.  ASW Food ( Asia Sakti Wahid ) hand wash machine, supply
    Terima kasih

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