WELCOME

TO
PT. CJ INDONESIA
Pasuruan Plant

TOP 21
TPM PT CJ Indonesia Pasuruan Plant
PT. CJ INDONESIA
TPM ACTIVITY
 VISION
NO. 1 COMPANY IN BIO BUSINESS
WITH GLOBAL COMPETITIVENESS

MISSION
ADVANCED TECHNOLOGY DEVELOPMENT
INNOVATIVE MANPOWER MIND SET
OPTIMIZE EQUIPMENT EFFECTIVENESS
 ORGANIZATION OF TPM PT CJ INDONESIA-PASURUAN PLANT

Top Management

Consultant TPM Center

Production Administration Global Biz Bio Dev Engineering AF

Lys Ferm HR Purch Ferm Cons Prod

Lys Ref GA Exim Ref Maint QA

Thr Ferm Acc Sales QC Utility Adm

Thr Ref Logistic LF Sales

MSG Ferm Env

MSG Ref

Recycling
ORGANIZATION OF TPM SECTION

Section Chief

TPM Center

Small Group Leader

Member
Member
Member
Member
Member
Member
Member
 CONDITION OF COMPANY

Plant area 34 ha
Production & Utility area 60%

Rotary Equipment
- Pump 961 pcs
- Reducer 351 pcs
- Other 52 pcs
Employee
- Permanent 730 persons
- Contractor 650 persons
GOAL OF TPM PT. CJ INDONESIA
PASURUAN PLANT

COST LEADERSHIP
INCREASE PRODUCTIVITY
REDUCE LOSS
INCREASE OPERATIONRATE
REDUCE TROUBLE
 TARGET OF TPM PT. CJ INDONESIA
PASURUAN PLANT

REDUCE
EQUIPMENT TROUBLE
95%
WITHIN 4 YEARS
(2005~2008)
 TROUBLE EQUIPMENT
PROGRESS & ESTIMATION
898 Mechanical Instrument Electric Total
900
850
800
750
700
650
600
493
550
frequency

500
450 368
400
350
300
250
200 118
150
90
44 21
100
50
0
2002 2003 2004 2005 2006 2007 2008

year
REMARK : ACTUAL ESTIMATION
 AVERAGE TPM ACTIVITY
PROGRESS & TARGET
30
25
25 22

18
20
hour/person

14.7
13.7 13.6 13.7
15

10

0
2002 2003 2004 2005 2006 2007 2008
year

REMARK : ACTUAL ESTIMATION

 ONE POINT LESSON
2500
2500 2250
2192
2072
2000
2000
EA

1500 1207
1059

1000

500
2002 2003 2004 2005 2006 2007 2008

year
REMARK : ACTUAL ESTIMATION
 SUGGESTION IMPROVEMENT
10209
9621
10000
8630
8150 8300
7868 7763
8000

6000
EA

4000

2000

0
2002 2003 2004 2005 2006 2007 2008

REMARK : ACTUAL ESTIMATION

 SUGGESTION IMPROVEMENT RESULT
25,000
26,000
58
24,000 21,959 22,000 54
Saving (Rp Million)

22,000 19,936 20,154 20,000

Reward (Rp Million)

18,956 52
20,000
50
18,000
48
16,000

14,000 46

12,000 44

10,000 42
2002 2003 2004 2005 2006 2007 2008
40

REMARK : ACTUAL ESTIMATION

 SIX SIGMA IMPROVEMENT RESULT
70
70
60
60
SAVING PER YEAR ($ MILLION)

60
50

Total Project (EA)

50
40
40 33

30 30
20.3

20 13.7 20

10 10

0
0
2003 2004 2005 2006

REMARK : ACTUAL ESTIMATION

 ENERGY CONSUMPTION TREND
Elect Steam
150

140

130 138.2
133.4
120 110.0
PERCETAGE

110 103.0 102.6

100.0
100
100.0
90 80.0
80 88.3 70.0
80.0
70

60 70.0

50
2002 2003 2004 2005 2006 2007

REMARK : ACTUAL ESTIMATION

Kick Off TPM Program
August 13th, 1998
TPM Slogan Board
Monthly Meeting
TPM Monitoring Board
Evaluation Direct Team
Evaluation Indirect Team
TPM Coordination
Training
Overseas Training
Comparison Study
PLANT
PLANT
PLANT
PLANT
PLANT
LABORATORIUM
STATIONARY
SPARE PART BOX
SECURITY GUARD
CANTEEN
Thank You