RESUME

MANUFACTURING SYSTEM AND INDUSTRIAL AUTOMATION

SMALL MEDIUM ENTERPRISE : CRACKER PRODUCTION
BULUSARI, TAROKAN, KEDIRI

FARINDITA FARDIN SINATRIA

02411740000077
Q CLASS
 MANUFACTURING SYSTEM RESUME
Small Medium Enterprise(SME) visit was done on Friday, 6 th of March 2020 at the SME’s
central of Cracker production, Bulusari village region, Kediri. The group was divided into two for Q
class,rfor Q1 the SME assigned was near the meeting point. Based on the time given by the comitte,
around two hours, for observation of the assigned Cracker SME, below are the data that can be
obtained and concluded.

1. Cracker SME Core Business Process

Following the CIMOSA structure below, further description can be made regarding the SME’s
core business process.

a. Develop Product: The product offered on the SME was only a bland-original flavored
cracker, the decision on the product being made and sold was solely because the
degree of level needed to manufacture the cracker is easy with a more stable
demand – that would always exists through all seasons.
b. Get Order: They implemented a mouth-to-mouth marketing base, with the targeted
market of cracker merchants in need of raw/un-cooked/un-fried crackers. Where
their customers were their acquaintance near the SME’s center, after that the initial
customers circle would tell another merchant in need of a raw/un-cooked crackers.
The SME’s have never done any active get order activity. Currently, their market base
is located throughout Ngawi, Madiun, Trenggalek, Camban, and even Surabaya.
c. Fulfill Order: Fulfilling the customer’s order are done from the raw material
acquisition process from the main ingredient supplier of flour ranges in location from
Mojo and Kaliboto region to the production process of:
Dough mixing and tubular shaping process  Cracker’s shaping into one tray (8 rows
x 14 columns) using half-automated system  Steaming the cracker’s in trays in
batch of 100  Drying process  Sorting and packaging into a sack
After the production process, the SME’s will fulfill its demand from their customer,
the way they provide the crackers is done in two methods:
- Customer comes directly to the SME’s location to obtain the product
- The product is sent to the customer with the delivery cost, including the
outsource worker needed to deliver it, passed on to the customer
d. Support Product: Their product support side from the packaging itself is done in a
bulk system using sacks with no information or brand attached, while for the
customer relationship management is done in a way where if there’s any complaint
from the customer, they would give a price discount by giving back the money to the
customer in a certain agreed percentage. While they will not accept the defected
 product to be sent back to their place, since it would cost more with no value can be
added to their business because they cannot re-use the defect product and transform
it to raw materials.

2. SME’s Identified Problem

The problem that can be identified from the observed SME’s based on the classification of
their business core processes are:
a. Product Development  Lack of variation in the product offered
b. Get Order  Passive way of getting customer, made their market area narrow. Losing
opportunity to widen their area and also their profitability.
c. Fulfill Order  Not fully automated machine used made the production time for a
500 kg of production/day slow and with a ranging specification of the cracker’s
thickness and such. Also, for the layout that is not efficient yet knowing that the
layout does not follow the process step – and kind of random placed, making the
material handling of transportation taking much time. While for the raw material
fulfillment from the supply, they did not conduct flour standardization meaning that
their cracker’s quality is not maintained at a certain targeted level. Aside from that,
the weather have a great impact on the fulfilling order process, because when it rains
the drying process will be gone making the production rate lower with the product
being stopped in the storage after steaming process.
d. Support product  No branding and information attached regarding the production
date, expiry date and other useful information, also the product packaging is not
hygiene.

3. Analysis + Improvement
a. The SME’s itself
Based on the core business processes problem identification, the conducted analysis
and improvement is as follows:
- Product Development
Lack of variation in the offered product will make a lost opportunity cost since the
current cracker’s variation is wide in the market, making the customers to get
bored easily with only one selection of crackers that the SME have. This problem
can be resolved by conducting a market research through interview and
observation in the crackers trend based on the season, so the SME will have
information on how to broaden their variation and knowing how to schedule the
production by a seasonal basis, so the profitability will be on its optimum point.
- Get Order
To make their profitability increases also means that they must get a higher
number of demands which comes from the customers. A wide customer network
is needed for all business to strive and grow in the competition, meaning that the
passive gets order way that the SME’s have done throughout these times is not
 enough to make the business grow. To tackle this problem, the SME can develop
a new division dedicated to market their product in regional event around Java
for SME’s that seldom held by its region government. If the development of a
new division is considered as too pricy of a move, then a small step of doing
workers outsource to look after marketing possibility in a certain region can be
the alternative way.
- Fulfill Order:
The fulfill order problems are closely related to the technological improvement
that can be explained further in the Industrial Automation Resume. While for the
supplier selection, the SME’s should conduct a decent observation regarding the
flour’s raw material processing or else can be done by comparing the result of
cracker’s produced on the same batch of manufacturing process to make sure
that the cracker’s were exposed to the same treatment. To minimize the weather
impact, the SME can use or invest on a substitute machine such as oven to dry
the crackers while it is raining or a solar panel system oven for a cheaper
electricity cost.
- Product Support:
To generate a greater brand reputation as a way of business marketing, the
package used should be standardized by having a specification on the important
information such as the expiry date and the brand name. For the hygiene part,
the SME can change its way of storing and packing into a more standardized
package based on the BPOM regulation, this will act as a product support in
which the customer would find the SME’s as a reliable supplier for their
needs/demands.
b. The SME as the component of SME Center
In the currently observed SME’s there are 9 others SME in their region that also
produces the same product with similar to slightly different variation of crackers.
When conducting the observation, it is found that there is no meaningful integration
on this SME’s center, such as their customer and demand fulfillment base. When the
integration of SME is important regarding:
1. Widening the market base by doing cracker’s variation by implementing a
dedicated workload throughout the SME’s center, that way the customer
targeted market will get bigger.
2. Aligning the information system by making a database for a better value
stream of the whole region, one of its benefits is to align the demand and
knowing the possibility of the demand number that cannot be met while
having another SME’s to cover for it
3. The value stream should go through one door/system, so the cost and pricing
of the SME center can be standardized.
 INDUSTRIAL AUOTMATION RESUME
Small Medium Enterprise(SME) visit was done on Friday, 6 th of March 2020 at the SME’s
central of Cracker production, Bulusari village region, Kediri. The group was divided into two for Q
class,rfor Q1 the SME assigned was near the meeting point. Based on the time given by the comitte,
around two hours, for observation of the assigned Cracker SME, below are the data that can be
obtained and concluded.

1. Initial machine/techology used

a. Processing machine
- Dough maker machine
The dough making process is done to create a crakers dough from the existing
raw material. The process have three steps in it, as follows.
Mixing the raw material (flour, salt, coconut milk) into a near-round shaper dough
 Re-mixing of the dough to gain a smoother texture (if there is a defect WIP
product in the cracker’s shaping process, it will be added here and re-mixed) 
Final mixing and shaping into a tubular shape as seen below.

- Cracker’s shaping machine

The final processed dough form of tubular shaper are then inputted into the
machine shown below for the process of shaping the dough into the intended
cracker’s shape for around 3.45 minutes per batch consisted of 6 dough,
following:
1. Putting the dough in the machine’s cutting board
2. Putting the tray in the starting point of the machine
3. Turn the machine on, then the step of how it works follow:
The conveyor belt and the cutting board’s knife will work/move simultaneously,
so the tray will move forward  the dough will be cut into the desired shape,
size, and amount per tray  the tray full of shaped crackers will come out in
the end point.
 4. If there is any defect produced by the machine, the operator will separated it
and putted away into a basket

- Steaming machine
The WIP product from the cracker’s shaping process will be stacked into a batch
of 100 trays and put inside the steam machine to make the cracker cooked with
moist texture for about 15-20 minutes. The energy of the machine comes from
the process of burning sawdust in a firebox.

b. Material Handling
- Hand-pallet truck
The material handling that is used in the SME manufacturing process is a
transporting type of a hand-pallet truck. This MH is used for transporting the
product in WIP process while placed in trays or carried in a bulk, which are:
1. The cracker’s shaping process  Steaming machine
2. Steaming machine  Steamed product storage
3. Steamed product storage  The yard used for drying process
4. Yard  Sorting and packing location
5. Sorting and packing location Final storage/warehouse
2. Identified Problem
a. Machine
- Dough maker machine
Un-efficient processing of the dough making because the mixing part has to be
done in three times to get the desired texture.
- Cracker’s shaping machine
Relatively slow process.
High defect rate because of simultaneous process between conveyor belt –
cutting.
Less or more of the desired cracker’s amount cut in one tray, because of
operator’s delay inserting the tray
- Steaming machine
The machine lack of hygiene with concrete as its base
Fixed type of machine, making it less feasible to improve the layout

b. Material Handling
- Hand-pallet truck
The use of hand pallet truck as its MH equipment is considered modern enough,
but because of other factor, layout of the production house, how they use the
MH is not efficient with a possibility to shorten the total moving time.

3. Analysis + improvement
a. Machine
- Dough maker machine
The mixing process is the initial step that leads all of the processes behind it,
meaning that if the time were made to be faster, then the total manufacturing
lead time would be smaller, hence enhancing the production rate of the cracker’s
SME. To accommodate it, the mixing and shaping into tubular form can be done
in one-go by accommodating the process with the suitable machine equipped
 with a stronger and compatible mixing device equipped with a tighter lid that
automatically pressed the raw material that is put inside, eliminating the need of
human energy to press it down.
- Cracker’s shaping machine
The machine can be adjusted by making a PLC-based system and setting the
machine’s speed based on the operator’s needs , in which the machine can be
equipped with a sensors so if there is no tray detected when the conveyor is
moving – then the cutting process will automatically put on hold. Also,
substituting the cutting piece with a sharper knife supported with a more stable
and precise handle that is equipped with sensor so that the thickness of the
crackers would stay the same.
- Steaming machine
The basic structure of the steaming machine can be changed into a transferrable
machine to accommodate layout change and other future possible problem, and
also making the base and all component from aluminum – like an oven. To
further increase the MLT, the machine can be changed by equipping it with a PLC
and fuzzy logic implementation, so the operator can control the temperature
needed to steam the cracker – with a display of the current temperature inside
the machine.

b. Material Handling
- Hand-pallet truck
To accommodate a better MH utilization, the layout of the SME should be
changed based on the sequence of production process so the moving time can be
decreased. Aside from the problem identified, advancing the material handling –
transportation system, is deemed to be feasible. The MH can be made fully
automated, working alongside the production’ layout from the initial process
until the storing before drying process and continuing from the sorting process
until finished goods storage. The automated system is supported with the use of
conveyor belt that is equipped with a PLC equipped with a sensor system to
direct the product by automatically pushing the product to its destination by
identifying if there is an object that meets the shape of the one coded in the
sensor system on the moving conveyor belt.
Attachment