INTRODUCTION
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Nama NIK Pendidikan Pengalaman
: Yusup H : 1105111 : S1 Teknik Mesin : Consultan design (2009-2010), (2009-20 10), Warehouse Staff (2010),
GENERAL PAPERMAKING PROCESS
Plantation
Finishing
Raw Material
Stock Preparation
Paper Machine
RAW MATERI MATERIAL AL Long fiber :
•
ONP ( Old newspaper )
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Recycled
paper, which has a content of 60-70% old newspaper, magazine max 30%, other paper & OCC includes 5% max
Short fiber :
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NBKP ( Needle Bleached Kraft Pulp ) NUKP ( Needle Unbleached Kraft Pulp )
LBKP ( Leaves Bleached Kraft Pulp )
BCTMP (Bleached Chemical Thermo Mechanical Pulp )
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Consisting Consisting of
old magazine, catalog & similar materials, including other paper & OCC 2%.
Short and long fiber •
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Broke ( Recycled Process)
OMG ( Old magazine )
Paper Machine , Finishing , return goods
SWL ( Sorted White Ledger ) office paper
OCC ( Old Corrugated Container )
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wrapping
)
paper (box) of food / goods goods ( brown brown color
CACO3 PROCESS
Precipitate d Calcium Carbonate
Ground Calcium Carbonate
CaCO3
1. PCC (Precipitated Calcium Carbonate)
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CaCO3 CaO + H2O Ca(OH)2 + Na2CO3
CaO + CO2 Ca(OH)2 CaCO 3 + side product
CO2 (NH4)2CO3
99.8 %
Pharmacy, food, milk, mineral water, toothpaste etc
2. GCC (Ground Calcium Carbonate) Size reduction •
Dispersant
15-30 cm
Crushing
<4 cm
Dry grinding
<45 m
Wet grinding
<2 m
75% solid
Screening
Storage
CRUSHING Type:
Jaw Jaw crusher
15-30 cm
<4 cm
DRY GRINDING Rooller Mill (VX Mill)
WET GRINDING Type:
Atrition Mill <45 m
Dispersant Water
Slot screen 0,3 mm
Ceramic bead
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 & ST STORAGE ORAGE
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) Filler (top layer) Ivory Filler (top layer & back layer)
Capacity : Capacity : 7,500 ton/month (dry) 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 PVA (Poly Vinyl Alcohol) Alcohol )
COLOUR KITCHEN •
Film press Surface sizing
enzyme
Native starch
converter
Jet cooker
COATING Function : Printability and print quality Paper appearance (gloss, brightness, bri ghtness, colour, colour, opacity) opacity ) •
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Components of coating process : Base paper Coating colour Coater machine •
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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 surface (smooth)
Binder Adhesive used to bond bond the pigment pigment particles to 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
Coating colour mixture of pigment + binder + co-binder + additives + water applied to base paper in the coating process
Storage tank
Working tank
COATING COA TING APP APPLICA LICATION TION
Working tank
STOCK PREPARATION •
131 – NBKP
: 65 T/d
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132 – LBKP
: 360 T/d
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135 – BCTMP
: 350 T/d
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136 – BCTMP
: 360 T/d
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140 – LBKP
: 250 T/d
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141 – BCTMP
: 250 T/d
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143 – LBKP T PULP: 60 T/d
VIRGIN PULP
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134 – FILLER I
: 360 T/d
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137 – BACK LAYER
: 230 T/d
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138 – REJECT HANDLING
: 60T/d
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142 – OCC
: 110 T/d
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133 – UNDER LAYER
: 260 T/d
WASTE PAPER
VIRGIN PULP Long Fiber HD CLEANER DUMP CHEST
REFINER
STORAGE TOWER
BLENDING CHEST
M/C CHEST
Short Fiber HD CLEANER DEFLAKER
DUMP CHEST
REPULPING
CLEANER
REFINER
REFINING
STORAGE TOWER
BLENDING CHEST
BLENDING
BRUSH REFINER
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 SECONDARY FIBER FIBE R Under Layer
DUMP TOWER
HD HOLE CLEANER SCREEN
SLOT SCREEN
FLOTATION
CLEANER PLANT
THICKENER
DISPERGER THICKENER CHEST
STORAGE TOWER
MIXING CHEST
M/C CHEST
Filler Layer HD CLEANER DUMP TOWER
HOLE SCREEN
M/C CHEST
CLEANER PLANT
SLOT SCREEN
FRACTIONATING
THICKENER
DISPERGER CHEST
CHEST
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 Sur face 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, Tensile, Folding etc) Example: Cationic Starch
3. DYES Function : to generate generate a standard color paper production, measured m easured using a test of L, a, b. Chemical : Basic Dyes ( Blue & Violet)
4. DEINKING CHEMICAL Function : to remove ink on waste waste paper (brightness will be higher) Chemicals : H2 O2 (Hidrogen Peroxyde), Peroxyde), NaOH NaOH (soda), Na Na 2 SiO3 (Sodium Silicate), Soap (detergen) 5. COAGULA COAGULANT NT & FLOCCULANT Function : Drainage , water purification 6. BIOCIDE Function : to prevent bacterial growth.
PM3/6 PROFILE
PM 3 Manufacturer Type
PM 6
Voith Sulzer, Germany Germany Fourdrinier Multilayer (4 plies) Completed with 4 on line sensor
Design Speed
600 M/Min
M/C Width
4.2 M 87 dryer
Cylinder Dryer 2 cooling cylinder Size Press Coater
Jagenberg, Germany 3 coating heads
4 coating heads
Jagenberg, Germany Rewinder 2,000 M/Min
Product
Duplex (DA,)
Ivory (IA, IF, IG, GV)
Triplex (T1)
Art Board (IS,SV)
Ivory (IA,)
PAPERMAKIN APERMAKING G FLOW FLOW DIAGRAM Wire part
Press part
Stock preparation
Main dryer
Size press
After dryer
Calender 1
Coater 1
Dryer
Coater 2
Coater 3
Calender 2
Cooling cylinder
Pope reel
Approach flow system
Rewinder
Roll handling
Finished goods
CHEMICALS AND ADDITIVES Chemical
Function
CaCO3
Filler & brightness
ASA Starch
Internal sizing (cobb (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 (Starch spray) spray)
filler
under
top
back
FORMER & VACUUM SYSTEM
Double side dewatering Very V ery gently and efficient dewatering dewatering Highest capacities possible Highest sheet strength, best formation
filler
under
top
back
Filler layer
Under layer
Back layer
Top layer l ayer
PRESS PART •
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Dewatering process by nip press (mechanical drainage) Consist of tri-nip press.
Guide roll
PRESS PART
20
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22 % 45
Stretcher roll
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50 %
SHOWERING SY SYSTEM STEM •
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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 •
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90
1
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90
95 %
3
2
4 80
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85 %
–
95 %
STEAM & CONDENSATE SYSTEM
15 bar
Coater
5.5 bar
Cylinder dryer
Co-GEN
Separator Condensate
SIZE PRESS ( FILM PRESS ) Function : Surface sizing (Starch addition) •
CALENDER Function : 1. Caliper Profiling 2. Sheet Gloss 3. Sheet Density
Consist of : Hard Nip Calender Soft Nip Calender
Hot Oil
HNC
HNC
HNC
SNC
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1st
2nd
COATER Function : 1. Printability & print quality 2. Paper appearance
Drying process : Hot air dryer ( steam 15 bar ) Infra Red dryer •
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COATING MACHINE CONFIGURATION
Top – top coat Top pre - coat Top layer Under layer Filler layer Back layer
POPE REEL Production code
C 0 4 30 15
Paper machine identity
Roll Number Date of production
Year of production Month of production PM 3 PM 6
:C :D
January - September October - December
:1-9 : A, B, C
REWINDER Winding position
C 0 4 4 3 0 1 5 Core diameter Roll position Number of winding
FINISHING B DEPARTMENT
FINISHING B DEP DEPARTMENT •
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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 Packing Section Quality Control ▫
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STRUKTUR ORGANISASI FINISHING B DEPARTMENT Kepala Department Finishing B
Kepala Seksi Finishing B Support
Kepala Seksi Cutting
Wakil Wakil Kepala Kepala Seksi
Wakil Wakil Kepala Kepala Seksi
Wakil Wakil Kepala Kepala Seksi
Wakil Wakil Kepala Kepala Seksi
Kepala Shift
Kepala Shift
Kepala Shift
Kepala Shift
Wakil Wakil Kepala Kepala Shift
Wakil Wakil Kepala Kepala Shift Shift
Wakil Wakil Kepala Kepala Shift Shift
Wakil Wakil Kepala Kepala Shift Shift
Kepala Regu
Kepala Regu
Kepala Regu
Kepala Regu
Wakil Wakil Kepala Kepala Regu Regu
Wakil Wakil Kepala Kepala Regu Regu
Wakil Wakil Kepala Kepala Regu Regu
Wakil Wakil Kepala Kepala Regu Regu
Operator
Operator
Operator
Operator
Kepala Seksi AMPS
QC Finishing Dept.
FINISHING B SUPPORT SECTION •
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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 B RSA untuk dipotong di Sheeter atau Winder sesuai memo (PBCR dan PRCR) 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. konsu men.
AUTO & MANUAL PACKING SECTION
Tugas :
Membungkus sheet hasil potongan sheeter dan mengemas sesuai packaging yang diminta costumer Mentransfer Finish Good ke auto warehouse melalui melalu i 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, PET, lakban, lakban, lem, layer) layer)
FLOWCHART FLOWCHAR T ACTIVITY FINISHING B DEPARTMENT DEPARTMENT Sheeter
Un Sortir
Ream Wrapping
Manual Wrapping
Sortir BRSA
Paper Roll dari PM #3/6
Semi Auto Wrapping Wrapping
Shringkage
Salvage Winder
Dari Rewinder PM B
Roll Wrapping
Strapping
Auto Warehouse War ehouse
ROLL RECHEIVING •
Roll diterima dari PM3/6 untuk diproses lebih lanjut di Finishing.
ROLL HANDLING
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Roll dari PM B distrapping untuk kemudian disimpan di base roll Untuk urgent order, order, roll di bypass langsung l angsung ke cutting area Roll yang order PRCR PRCR lewat lewat bypass untuk menyingkat waktu
ROLL HANDLING Roll yang masuk dalam PBCR, dari slat conveyor conveyor dipindahkan dipindahkan ke area cutting dengan travelling kicker oleh operator
BASE ROLL ST STORAGE ORAGE AREA
Roll yang tidak masuk ma suk dalam PBCR atau PRCR disimpan di Base Roll Storag S toragee Area untuk keperluan stock Base Roll Spesification
Capacity Total (A+B) : 15,000 Ton Roll Diameter
: 1.2 – 2.1 m
Roll Width
: 0.6 – 2.20 m
Roll Weight
: 1,000 – 6,000 Kg
Roll High/Pile
: 0.6 – 12 m
CUTTING SECTION
SALV SAL VAGE WIND WINDER ER 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 Paperbo ard 250-500 g/m2
SKEMA SKE MA SAL SALV VAGE WINDE WINDER R PASABAN PASABAN Guide Roll Web Rider Roll
Roll Unwind
Roll Winding
Core Chuck
Banana Roll Slitter
Drum Roll
SALVAGE WINDER YUE LI Yue Yue lie lie Spesification Spesification Machine Supplier You lie Machinery Paper width 2200 mm Design speed 1500 m/min Basis weight 210-500 g/m2 Finished roll core diameter
Paper quality
6”,10”, 12” Board
SKEMA SALVAGE WINDER YUE LI
Roll Unwind
Rider Roll Roll Winding
Guide Roll
Core Chuck
Web Slitter
Drum Roll
SALVAGE WINDE SALV WINDER R GREA GREAT T WALL (BARRI ( BARRIER ER 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
Guide Roll
Core Chuck
Roll Winding
Web
Coater
Roll Unwind Slitter
Drum Roll
SALV SAL VAGE WINDE WINDER R PROCESS PROCESS
1
3
SALVAGE WINDER (SW) PROCESS 1. Pasang paper core. 2. Setting Slitter. 3. Pasang paper roll.
2
QUALITY CHECK
Check kualitas winding Check Size order Roll disusun sesuai sesu ai order dan label
SALVAGE WINDER PRODUCT AREA
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Roll disusun sesuai se suai order,label order,label diletakkan diletak kan di dalam paper core Pemasangan core plug Pemasangan carton sheet
ROLL WRAPPING PROCESS
MESIN ROLL WRAPPING 1
MESIN ROLL WRAPPING 2
AUTO AUT O ROLL WRAPPING PROCESS FLOW
Winder
Conveyor
Kicker
Auto Wrapping
Labeling
Strapping
Kicker
Elevator to AW
SEMI AUTO ROLL WRAPPING PROCESS FLOW Winder
Conveyor
Kicker
Semi Auto Wrapping
Conveyor
Labeling
Strapping
Kicker
Elevator to AW
SHEETER PROCESS
Sheeter Machine Machine Profile Old Pasaban Quantity : 6 units Capacity : 42 Ton/Mc/Shift
New Pasaban Quantity : 2 units Capacity : 50 Ton/Mc/Shift
Will Pemco Quantity : 4 units Capacity : 32 Ton/Mc/Shift
Saito Quantity Capacity
: 1 unit : 5 Ton/Mc/Shift
Tai Yong Quantity Capacity
: 2 units : 10 Ton/Mc/Shift
SKEMA M/C SHEETER Guide Roll
Decurler Nip Roll Cross Cutter
Slitter
Outle t
Jogger
Overlap
Web Banana Roll Roll Unwin d
Drum Roll
Fast Belt Slow Belt
Sheet Stack Pallet Stacker/ Lay Boy
M/C SHEETER
UNWIND
GUIDE ROLL
DECURLER
NIPP ROLL
TRIM VACUUM
SLITTER
FAST BELT
SLOW BELT
OUTLET
BANANA ROLL
JOGGER
SHEETER OLD PASABAN PASABAN (2,3,8,9,10 & 11)
Machine Specification :
Machine Width
: 2300 mm
Maximum Web Width
: 2200 mm
Mother roll dimensions : Maximum roll width Minimum roll width Maximum roll diameter Minimum roll diameter Mother roll core diameter
: 2300 mm : 430 mm : 2100 mm : 600 mm
: 10” & 12”
Maximum mechanical speed
: 300 m/ menit
Cut sizes:
Minimum slitting width
: 300 mm
Maximum sheet length
: 1600 mm
Minimum sheet length
: 400 mm
Maximum pile height
: 1600 mm
Maximum knife load at the crosscut
: 600 GSM
Material to be processed
: Card board
Material grammage
: 250-500 GSM
SHEETER NEW PASABAN 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
2300 mm
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
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) •
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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 (Visual,Order,, Size)
QUALITY CHECK Macam-macam abnormal sheet: Botak Garis Gelombang Wrinkles Wrinkles Marking Melipat / terjepit GSM campur Kertas basah Calendar mark Coating jelek Bintik hitam Lubang Sobek pinggir
BUFFER AREA (AFTER CUT AREA) •
Tempat paper paper sheet setelah turun tu run dari sheeter dan menunggu proses selanjutnya di AMPS
SORTIR
Sortir dilakukan dengan tujuan untuk mengindari produk (kertas) yang tidak memenuhi memenuhi spesifikasi (abnormal) (abnormal) terkirim terkirim ke costumer
AUTO & MANUAL PACKING SECTION (AMPS)
SHEET WRAPPING PROCESS FLOW
Buffer
Wrapping Wrapping
Labelling
QC
Shrinking / Stretching
Strapping
QC
AW
PROSES 1. AUTO , SEMI SEM I AUTO & MANUAL WRAPPING
Proses pembungkusan Paper Sheet menggunakan Sheet Laminating 2. LABELING Penempelan label pack dan label pallet 3. AUTO AUTO & MANUAL SHRINKAGE SHRINK AGE 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 transfer produk ke bagian Auto Warehouse Warehouse
AUTO REAM WRAPPING AUTO (WRAPMATIC) •
Total
: 5 unit
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Max Speed
: 15 ream/min
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Ream Paper Substance Substa nce
: 60 – 400 gr/m
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Max Ream Weight
: 40 Kg
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Wrapping Wrapping Material
: Kraft Poly Poly Coated Coated
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Substance Substa nce
: 80 – 120 gr/m
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Glue Type
: Hot Melt
Pallet Size Wide Length Height
: 440 – 1000 mm : 550 – 1400 mm : 100 mm
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Production Productio n Target Target : 4500 pack/MC/shif 80 ton/MC/shift Operator outsourching)
: 3/shift (2 karyawan + 1
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) •
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Khusus costumer dari negara beriklim dingin (Amerika, Jepang) Dikerjakan dalam ruangan tertutup ber-AC ber- AC Tujuan : Untuk menyesuaikan suhu saat membungkus kertas dengan suhu di negara tersebut (+ 22 oC) Untuk mengurangi kontaminasi debu dan kotoran Proses : Secara umum identik dengan auto wrapping Pembungkusannya dilakukan secara manual menggunakan lakban –
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PROCESS FLOW SEMI AUTO WRAPPING
SHEET
SHEET
REAM FEED GUN
REAM FEED GUN
BELT CONVEYOR
BELT CONVEYOR
LAMINATING PAPER
WRAPPING (lakban manual)
LAMINATING PAPER
–
WOOD PALLET STACKING (slat bar)
WRAPPING (lakban manual) –
LABELING
WOOD PALLET STACKING (slat bar)
SHRINGKAGE
LABELING
STRAPPING STRAPPING
STRAPPING
HANDED TO AW
HANDED TO AW
SEMI AUTO WRAPPING •
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Maximum Speed Ream Pape Substance Production Target Maximum Ream Weight Total Glue Type Operator Wrapping Wrapping Material Substance Jenis : Cokelat Putih Savicoat –
: 5 pack/min : 60 – 400 gr/m : 2000 pack/MC/shif pack/MC/shi f : 40 kg : 2 unit : Lakban Lakba n ( ADH Tape) : 3/MC/shift : Kraft Poly Poly Coated Coated : 80 – 120 gr/m ²
²
MANUAL WRAPPING •
Khusus produk Ream Wrapping Menggunakan pallet plastik (after sheeter) –
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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 –
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Perekat = Lakban plastik (ADH Tape)
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100% tenaga manusia (ibu-ibu)
PROCESS FLOW MANUAL WRAPPING
SHEET (AfterCut)
SHEET (AfterCut)
LAMINATING PAPER
LAMINATING PAPER
WRAPPING (lakban)
WRAPPING (lakban)
WOOD PALLET STACKING (manual)
WOOD PALLET PALLET STACKING (manual)
LABELING
LABELING
STRAPPING
S HRINGKAGE
STRAPPING
HANDED TO AW
HANDED TO AW
MANUAL WRAPPING •
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Tenaga : Karyawan Outsourching Target Produksi : Karyawan Outsourching Outsourching
: 2 orang/pasang x 3/shift : 2 orang/pasang x 3/shift : 850 pack/shift : 800 pack/shift
LABELING • •
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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 •
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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
LABELING •
Untuk kertas downgrade, pallet berwarna putih dan berukuran A4, peletakannnya peletakannnya berada di bagian tengah pada bag.lebar dari pallet
Pack Label
Pallet Label Ukura n A4
AUTO SHRINKAGE FILM •
Mesin : 1. Robopack Senior 2. Octopus Hailola (nonactive) 3. OMS
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Bekerja secara otomatis Dilengkapi dengan line konveyor yang terhubung dengan Wrapmatic, Strapping, dan Elevator AW AW
ROBOPACK SENIOR •
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Membungkus Membungkus sheet menggunakan plastik dengan cara dililitkan secara melingkar Material : LDPE 60 µm 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 rpm Max Capacity : 60 pallet / jam
PROCESS FLOW ROBOPACK 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 µm 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 µm Produksi : 40 pallet/jam Temperatur empera tur : 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 (ROBOP (ROBOPACK ACK JUNIOR)
Batteries Jumlah lilitan
: 12 volt 8 A : 3 atas atas + 2 tengah tengah + 3 bawah Wheel size : 260 x 70 mm Ukuran stretch film fil m : 50 cm x 30µm Kapasitas Maximum Maximum : 1 pallet / menit
PROCESS FLOW ROBOPACK JUNIOR
MANUAL WRAPPING
LABELING
SHRINGKAGE PROCESS
STRAPPING
HANDED TO AW
AUTO AUT O STRAPPING STRAPP ING BAND
Equipment Data: Merk Berat Selling time Strapp feed Tension ensi on Strapp width Strapp thickness
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
: Messersi Packaging : 81 kg : 2 sec : 4 Ms/sec : 200 – 2400 N : 10 – 15 mm : 0.4 – 0.9 mm
POLLAR PROCE PROCESS SS Alasan utama mengapa produk harus harus melalui melalui proses 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 Sheeter •
•
•
POLLAR PROCESS FLOW SORTIR
SORTIR
RESIZE WITH POLLAR MACHINE
RESIZE WITH POLLAR MACHINE
SORTIR
SORTIR
MANUAL WRAPPING
LABELING
LABELING
SHRINGKAGE
SHRINGKAGE
STRAPPING
STRAPPING
HANDED TO AW
HANDED TO AW
PACKING SHEET S HEET DESIGN Top Heigth = 0.6 cm
TOP
Bottom Heigth = 13.8 cm - 15 cm
ASIAN NONSTOP PALLET
PACKING SHEET S HEET 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 WRA PP PACKING PACKING “M” JEP JEPANG ANG
NON REAM PACKING “Q” SPECIAL
NON REAM PACKING “Q” JEPANG
NON REAM PACKING “Q” BRAZIL
NON REAM PACKING PACKING “J,K,P J,K,P” ”
NON REAM PRINTING PACKING “R”
REAM WRAPP WR APP PACKING PACKING “U” UNP UNPALLET ALLET
Slip sheet
NON REAM PACKING “K”
ROLL PALLET PALLET DESIGN Bottom Heigth= 15 cm
PACKING “0”
ROLL UN PALLET PACKING “1,2,7,8 “1,2,7,8” ”
ROLL PALLET PACKING “3,4,5, “3,4,5,6,9” 6,9”
PROBLEM SOLVING •
Less Pack (Pack Kurang)
Solusi : adanya pengecekan jumlah pack oleh QC Packaging sebelum sebelu m produk ditransfer ke AW AW
PROBLEM SOLVING
Strapping miring
Solusi : Pengecekan Pengecekan packing oleh QC Packaging hendaknya lebih teliti sebelum produk ditransfer ke AW Mechanic/ Electric segera memperbaiki mesin strapping jika hasil strapping tidak sempurna.
Acknowledg Acknowledgee by by
Checked by
Presented by
Tsai Cheng Chi
Rul Ngaini
Yusup Yusup H
