ATUM SYSTEM (Average Tobacco Usage in Monthly Basis)

1. Receiving and shipment system

 Receiving
Receiving is done at the warehouse according tobacco type (for example receiving Madura is done at warehouse 6,
Background
and receiving FC Lombok is done at warehouse 2)
Uncontrollable beetle population in warehouse  Shipment
All warehouse are active at the same time need more resources
Due to scattered tobacco type storage in across warehouse resulted more beetle infestation Shipment is carried out in accordance with the order from the primary, to collect materials worker will take it from
Fumigated tobacco are mixed with old stock which is already infested by beetle the warehouse and collect it in 1 wingbox
There is no opportunity to full free up the space of warehouses for warehouse maintenance
Business contigency plan is not exist in place
Goal target

Current Condition
To develop new warehouse system in order to reduce beetle, improve effectiveness, more efficient and cost saving

Counter Meassure

One gate warehousing system

Storage is composed according to monthly usage
Tobacco type arrangement in warehouse followed by tobacco preference of beetle

Action Plan

Data inventory warehouse Mapping warehouses capacity, and standarize size for each section
First trial will be conducted on warehouse 4, and monitoring for 1 years
Beetle per Month

Team : TC Management
Dept Leader : Mr. Bambang Soerjo
 I Background

"One of the biggest assets of the company is raw material, so in the storage process, it must be well-conditioned. But what is happening right now, beetle
is difficult to control because the warehouse arrangement is not optimal. At present the warehouse arrangement is based on the type of tobacco, which
causes all warehouses to always operate because almost every day TC carries out deliveries to primary. In addition, some types of tobacco are preferred by
beetles, so it is possible that beetles will increase in warehouses that store oriental tobacco and flue cured. Fumigated new tobacco receipts will also be
mixed with old stock that has been infested by beetle. At present TC is having trouble doing warehouse maintenance such as repairing cracking in the
floor, repairing cracks in the wall because the warehouse is always filled ”

Stock Based on Packaging

Farm bale
1%
II Current condition : Stock Condition
 Our Stock Based on Type
Warehouse Size( loading 2019. Sep Storage Details based on end of September 2019
㎡) C48 rate
99%
 Available Lamin Rajanga OT
Stocks (%) CL Total
(Max) a n M
1 2,526 1,900 488.6 26 408.6 - - 80.0 488.6
2 4,551 3,700 1,634.5 44 1,589.4 39.4 5.7 - 1,634.5
3 1,155 825 589.5 71 - - - 589.5 589.5
4 1,980 1,475 165.1 11 44.0 - 121.1 - 165.1
5 1,650 1,155 715.8 62 - - - 715.8 715.8
6 5,117 3,231 1,662.8 51 - 1,662.8 - - 1,662.8
SKM 1,163 698 49.5 7 - - - 49.5 49.5

18,142 12,984 5,305.8 41 2,042.0 1,702.2 126.8 1,434.8 5,305.8

Stock based on Crop Year

old crop
46%
new crop
54%

New crop : 2,100 Ton, Old Crop 1,700 Ton

Farmer Bale (Kasturi 3) Old Crop Condition

II Current condition : Beetle per Month

Beetle Monitoring
Beetle Monitoring WH.3
WH.6
1,800
70
1,600
60
1,400
50
1,200
40
1,000
30800
600
20
400
10200

- -
1 1 2 3 4 5 2 6 7 8 9 10 3

Jan
Jan Feb
Feb Mar
Mar Apr
Apr May
May
Jun
Jun Jul
Jul Aug
Aug Sep
Sep Dec
Dec
 Beetle Monitoring WH.2
WH.4
WH.1
400
120
2,000 Beetle Monitoring WH.5
1,800
350
100
1,600 40
300
1,400
80 35
250
1,200 30
1,000
200
60
25
800
150
40
600 20
100
400
20 15
50
200 10
- -
11 2 23 2 4 35 36 47 8 4 9 5
-
Jan
Jan Feb
Feb Mar
Mar Apr
Apr May
May 1 2 3 4
Jun
Jun Jul
Jul Aug
Aug Sep
Sep Dec
Dec
Jan Feb Mar Apr May
Jun Jul Aug Sep Dec

Beetle is mostly in warehouse 6 (Rajangan) and warehouse 2 (Domestic lamina + offshore lamina old crop). In February - April the
beetle in the warehouse reaches> 1000. This is caused by in that month TC receives domestic tobacco, so warehouse 6 and
warehouse 2 always open

II Current condition : Warehouse Condition

 Main problem in warehouse are cracking in
floor and wall. But we difficult to do
maintanance because warehouse always
filled. So we just do cleaning use vacum
cleaner especially in the crack

II Current condition : Receiving System

WH 2
Lamina

WH 6
Rajangan Receiving is done at each warehouse. However, new fumigated tobacco will be
mixed with old tobacco that has been infested by beetle.

WH 4
OTM
II Current condition : Shipment System

WH 2

WH 6
Collect the tobacco from each
warehouse based on their order
Send to primary

WH 4
With this system shipment is not efficien because :
1. Workers must move around when taking goods
2. Wasteful diesel, because forklifts must move between warehouses
3. All warehouses will always be open, resulting in beetles from outside
will enter the warehouse
III Goal

Improve effectiveness and efficient :

- Shippment to primary
“To develop new warehouse system in - Man power
- IPM management
order to reduce beetle, improve
effectiveness, more efficient and cost saving Cost Saving :
“ - Fuel
- IPM management (fumigation, spraying and fogging)

IV Counter measure : 1. Advantage of ATUM System

ATUM system
 Cost Saving :
Improve effectiveness and efficiency :
- Fuel
- Shippment to primary
Forklifts only focus in 1 warehouse, no need to move to another
Prepare goods for shipment is easier because all goods are
warehouse
located in 1 place. If TC do fumigation, other warehouses can
Annual Monthly Weight per Σ
backup
Common to shipStock
Name the goods
Usageto primary
Usage carton Collie
Precentage - IPM management (fumigation, spraying and fogging)
IB3H 53,800 318,620 26,552 200 133 5.10%
- Man power
FC RRT XZFS 43,326 30,204 2,517 200 13 0.48% If the beetle is above the threshold, spraying / fumigation just
FC Lombok MBO 03 - 152,899 12,742 99.1 129 4.94%
FC India BL4F 84,859 147,759 12,313 199.2 62 2.37% done in the 1 warehouse and the other warehouses can still
Workers just focus prepare tobacco in one warehouse, no need
BAB5R 5,000 51,285 4,274 200 21 0.82% operate (Current condition, we fumigate all the warehouse)
to move to another warehouse
FC RRT HCXB 150,066 83,667 6,972 194.2 36 1.38%
FC India IWL2 5,538 4,770 398 197.8 2 0.08%
Philipine FCL 480,810 161,657 13,471 199.1 68 2.60%
- IPM management
FC RRT HCBC 32,980 17,605 1,467 194 8 0.29%
FC RRT HCXA 114,522 136,349 11,362 194.3 58 2.25%
Focus IPM management in operating warehouses, making
Philipine MB 30,848 22,833 1,903 192.8 10 0.38%
Maesan B 223,400 122,749 10,229 200 51 1.96%
observation easier.
Paiton B 243,957 194,719 16,227 198.5 82 3.14%
Besuki ZZ 26,658 95,226 7,936 59.6 133 5.11%
Fines Tanzania 9,711 17,848 1,487 149.4 10 0.38%
Fines Brazil 12,284 24,589 2,049 149.8 14 0.53%
Expanded Stem 8,125 52,973 4,414 65 68 2.61%
Turkey Sark CU 196,029 519,836 43,320 189.4 229 8.78%
Thailand Prilep KP 60,200 221,990 18,499 140 132 5.07%
Prilep DKP 102,760 172,926 14,410 140 103 3.95%
Prilep BG 83,020 150,696 12,558 140 90 3.44%
MAC 186,840 213,213 17,768 180 99 3.79%
Madura B 462,413 569,625 47,469 198.5 239 9.18%
Weleri ZZ 16,277 24,249 2,021 198.5 10 0.39%
IV Burley 3
Kasturi 1
Counter measure : 1. Storage Based on Monthly Usage
147,600
86,400
127,235
88,034
10,603
7,336
200
200
53
37
2.04%
1.41%
Kasturi 2 ZZ 219,400 275,053 22,921 200 115 4.40%
KASTURI 3 54,896 208,765 17,397 100 174 6.68%
INDIA JCDK 2,162 21,229 1,769 196.5 9 0.35%
Garut ZZ 1,710 22,349 1,862 80 23 0.89%
Temanggung C ZZ 44,420 101,735 8,478 218 39 1.49%
Pakpie B '15 43,603 66,332 5,528 199.1 28 1.07%
Pakpie C '15 22,732 29,242 2,437 199.4 12 0.47%
Pakpie B '18 305,200 296,548 24,712 200 124 4.74%
Pakpie C 'ZZ 21,000 14,153 1,179 100 12 0.45% Maximum Capacity Warehouse
Warehouse Monthly Usage
Stem Pakpie 6,334 8,526 711 88 8 0.31% (Kg) Capacity (Month)
Stem Madura ZZ 32,993 14,829 1,236 222.1 6 0.21% 1 1,900,000 410,329 4.6
Stem Maesan 10,480 13,346 1,112 199.9 6 0.21% 2 3,700,000 410,329 9.0
Rajang Lombok B 57,880 44,698 3,725 80 47 1.79% 4 1,475,000 410,329 3.6
Rajang Lombok C 33,840 83,588 6,966 60 116 4.46% 6 3,231,000 410,329 7.9
Total 3,724,070 4,923,951 410,329 - 2,604 100%
 IV Counter measure : 1. Storage Based on Monthly Usage (Layout)

Current Condition :
Warehouse 1 just used for offshore lamina tobacco.

Next Plan :
Warehouse 1 used for all tobacco based on monthly usage.
Warehouse 1 can used for 4 month, so that for 4 months, only 1
warehouse will be opened for shipment. After the warehouse is
empty, the warehouse will be completely repaired and prepared
for receiving new goods

Counter measure : 2. tobacco type arrangement in warehouse followed by tobacco Preference of

IV beetle (Layout)
 Oriental tobacco have a strong aroma, so oriental should not
placed beside the door. Because it will be invite the beetle at
outside warehouse.
In this layout, AC tobacco placed beside the door, because AC
have a low sugar and less aroma (and have amoniac aroma) so
beetle will dont like it

V Action Plan

No Activity Timeline
1 Mapping warehouses capacity, and standarize size for each
End of Oct 19
section
2 First trial will be conducted on warehouse 4, and
Nov 19 – Nov 20
monitoring for 1 years
3 Move 165 tons stock from wh 4 to wh 6 Nov 19
4 Warehouse maintanance (sealed all floor and wall cracking) Dec 19
5 Receiving domestic tobacco based on monthly usage March 20