proses produksi

1. MAIN OFFICE & JAKARTA FACTORY
KAV. A-1 BEKASI FAJAR INDUSTRIAL ESTATE
MM2100 INDUSTRIAL TOWN, CIBITUNG
BEKASI 17520, WEST JAVA – INDONESIA
TEL : (62-21) 898 – 0320 (HUNTING)
FAX : (62-21) 898 – 1092, 898 – 1063, 898 – 1118
SEMARANG FACTORY
Jl. DR. SETIABUDI 104, SUMURBOTO 50269
SEMARANG - INDONESIA
TEL : (62-24) 747 – 4447 (HUNTING)
FAX : (62-24) 747 - 2450
MT Periodic Report
Quality Assurance Division
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Mentor: Tri Nurdhanto
Co-mentor: Waris Andika

2. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Outline Presentation
Key Learning
Objectives
Activity
Timeline
Assignment’s
Overview
OUTLINE

3. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Quote
With or without a plan, there’s
a chance of failure. Planning
award purpose and offers
control of things.

4. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
1. Key Learning Objectives
1. Quality Activity on PT Fumira Jakarta Factory
2. Implementation of Workload Analysis Method to Review Full
Time Equivalent Quality Activity on Continuous Galvanizing
Line

5. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
• Quality Activity
CGL
• Quality excellence
& PDCA concept
• Brief explanation
about WLA
8/3-11/3
15/3-19/3
•Quality Activity
CGL based on
WLA
•WLA concept and
data implementation
from QC CGL
•Brief explanation
about CCL process
•Quality activity
CCL
•Quality activity
Finish Product
•Supplier quality
issue
22/3-26/3
29/3-1/4 (plan)
•Basic leadership
concept
•Data management
•Standardization
•Quality issue
customer
5/4-9/4 (plan)
Week
1
Week
3
Week
5
Week
2
Week
4
2. Activity Timeline

6. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3. Assignment’s Overview Week 1
3.1. Observing Quality Activity on CGL
Zinc coating test Measure the dimension
of the strip Bending test

7. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Tensile strength test Ball impact test Hardness test
3. Assignment’s Overview Week 1
3.1. Observing Quality Activity on CGL

8. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3.2. Observing Quality Activity on CGL based on WLA
3. Assignment’s Overview Week 2
Data
collecting
activity
Observing Q-
Act CGL (Zinc
Pot Comp.)

9. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Workload Analysis is an activity to calculate the number of people and the time needed to do a
certain job.
Effective
Not
Effective
Value
Adding
Effective
Effective
Non-Value Adding Activities
3. Assignment’s Overview
3.3. Workload Analysis
3.3.1. Definition of Workload Analysis (WLA) Method

10. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3. Assignment’s Overview
3.3.2 Implementation Step for WLA
There are 3 main steps for the implementation of Workload Analysis (WLA) method:
Step 1. Specify the scope of the analysis quality
The analysis is focused on the inspection Activity on CGL. This include the incoming process that
is checked by QC inspector especially for CRC 0,2 mm thickness.
3.3. Workload Analysis
Incoming
Continuous
Galvanizing
Process
SPM
Hardness & Uji
Tarik
Dimensi
Defek visual
inspeksi
Komposisi &
temperature
zinc pot
TLV

11. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Chromate
Passivation
Delivery
Konduktivitas
dan temperatur
kondensat
Konsentrasi
dan temperatur
chromate
Defek visual
inspeksi
Dimensi
Uji impak
Uji kekerasan Berat coating Uji tarik
Uji bending
3. Assignment’s Overview
3.3.2 Implementation Step for WLA
There are 3 main steps for the implementation of Workload Analysis (WLA) method:
Step 1. Specify the scope of the analysis quality
The analysis is focused on the inspection Activity on CGL. This include the incoming process that
is checked by QC inspector especially for 0,2 thick CR.
3.3. Workload Analysis

12. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3.3.2 Implementation Step for WLA
Step 2. Analyze the detail of work’s flow
process (with assistance from Mr. Waris
Andika)
After following QC inspector working, we list
all type of activities done by the inspector. Then
specify the time that each activity takes.
3. Assignment’s Overview
3.3. Workload Analysis

13. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3.3.2 Implementation Step for WLA
Step 3. Calculate the workload (with assistance of Mr. Tri Nurdhanto)
Summary:
1. For 0,2 mm CCR thickness, the inspector workload is under 80%. As the thickness increase, the
inspector workload increased drastically.
2. Walking between delivery CGL to Lab CGL is classified as non-value added which can be
improve in the future based on existing condition.
16.4
6.5
58.9
9.8 4.8
96.3
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0,25 mm-0,45 mm
26.6
9.7
84.4
13.2
4.8
138.6
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0,5mm-1,2mm
Kind of Activity
Workload(%)
17.9
6.2
36.0
8.7 4.8
78,5
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0,2 mm
3. Assignment’s Overview
3.3. Workload Analysis

14. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3.4. Observing Quality Issue on Cold Roll Coil (CRC)
Case: 0,2 mm thickness was inspected and found to be rusted on CRC
Rust on the CRC surface Rust on the CRC side
Inspection in the raw material warehouse
3. Assignment’s Overview Week 3

15. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3. Assignment’s Overview Week 3
3.5. Observing Quality Activity on CCL with Mr. Waris
Quality activity on CCL production is divided by three main process, which is Entry CCL
(raw material, parco, and bonderite), Center CCL (visual inspection), and delivery CCL
(color product)
Entry CCL Center CCL
Defek visual
inspeksi
pH &
Konsentrasi
Bonderite
Temperatur ,
Konsentrasi ,
dan pH Parco
Defek visual
inspeksi

16. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3. Assignment’s Overview Week 3
3.5. Observing Quality Activity on CCL with Mr. Waris
Quality activity on CCL production is divided by three main process, which is Entry CCL
(raw material, parco, and bonderite), Center CCL (visual inspection), and delivery CCL
(color product)
Delivery CCL
Defek visual
inspeksi
Ujitebal lapis
color
DeltaE color UjiImpak
Uji bending
Erichsen
Cupping Test
Cross cut
Pencil
hardnesstest

17. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Color Test Bending Test Erichson Cupping
3. Assignment’s Overview Week 3
3.5. Observing Quality Activity on CCL with Mr. Waris

18. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Ball Impact Test Paint Thickness Test Rubbing Test
3. Assignment’s Overview Week 3
3.5. Observing Quality Activity on CCL with Mr. Waris

19. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3.6. Observing Quality Activity on Finish Product with Mr. Waris
Shearing line /
Laminating
Forming
Dimensi (panjang, tebal, dan lebar), panjang
diagonal, dan visual inspeksi
Dimensi (panjang, tebal dan lebar) dan visual
inspeksi
Corrugating
Dimensi (panjang, tebal, dan lebar), berat, dimensi
corrugating, dan visual inspeksi
3. Assignment’s Overview Week 3

20. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Small Coil
Dimensi (Panjang counter & aktual, tebal dan lebar)
dan visual inspeksi
Attachment Pengecekan berdasarkan standard profile
Observing
Corrugating line
with Mr. Waris
3. Assignment’s Overview Week 3
3.6. Observing Quality Activity on Finish Product (FP) with Mr. Waris

21. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3. Assignment’s Overview
3.7.1 Visual Management Information Board
Planning
PAPAN INFORMASI
PEOPLE
GENERAL INFORMATION
QC ACTIVITY
TATA TERTIB
JADWAL SHIFT MINGGUAN
TUJUAN DAN TARGET MUTU
DEPARTEMEN
KRITERIA GI 0,2 COLOR
HARD
STANDAR KETEBALAN
DAFTAR KONTAK
DARURAT
ALAT PENDUKUNG QCD
KALENDER
NAMA DEFECT GI DAN COLOR
COIL/SHEET
PROGRESS QUALITY FEB. 2021

22. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
No Waktu Kegiatan
1 15 Maret 2021 Mendiskusikan rencana
manajemen visual ke SPV
Laboratorium CGL
2 18 Maret 2021 – 22 Maret 2021 Eksekusi
3 23 Maret 2021 Evaluasi
3. Assignment’s Overview
3.7.1 Visual Management Information Board
Planning

23. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
3. Assignment’s Overview
3.7.1 Visual Management Information Board
Inprogress
PIC: SPV at CGL Lab

24. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Latar Belakang Pemilihan Masalah
• Adanya papan laporan quality harian
yang tidak dimanfaatkan sejak 10 Juli
2020
• Pengintegrasian problem & problem
solving seluruh departemen di QA
PIC: SPV at CGL Lab (TBC)
3. Assignment’s Overview
3.7.2 Visual Management Quality Assurance Board
Planning

25. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
Manfaat
• Semua anggota mengetahui kondisi
terkini di QA.
• Brainstorming pemecahan masalah di
QA dapat dilakukan oleh semua
anggota.
QUALITY ASSURANCE BOARD
No Tgl/Bln Problem Type Problem Status Ket.
• Memudahkan briefing leader yang
dilakukan setiap pagi.
PIC: SPV at CGL Lab (TBC)
3. Assignment’s Overview
3.7.2 Visual Management Quality Assurance Board
Planning

26. Mentor: Tri Nurdhanto
Co-mentor: Waris Andika
Prepared By: Muhammad Fajar Asri & Vincent Alfianto
No Waktu Kegiatan
1 29 Maret 2021 Mendiskusikan rencana
manajemen visual ke SPV
Laboratorium CGL & QA Manajer
2 30 Maret 2021 – 31 Maret 2021 Eksekusi
3 5 April 2021 Evaluasi
3. Assignment’s Overview
3.7.2 Visual Management Quality Assurance Board
Planning