1.

1 Production Quantity - Actual vs Target

MANUFACTURING PERFORMANCE SUMMARY 2013

Jul-13 TOTAL YTD

Bukit Indah Babadan Gresik Makassar Palembang Manado TOTAL AOP target Remark TOTAL AOP target Remark

- Cup

Fruitamin Strawberry 220,779 447,662 223,500 41,765 71,858 35,014 1,040,578 1,527,174 68% 8,273,113 10,647,601 78%

Fruitamin Orange 24,337 25,668 - - - - 50,005 47,823 105% 284,255 315,091 90%

Fruitamin Blueberry 24,098 30,964 - - - - 55,062 40,609 136% 208,871 276,493 76%

Fruitamin Fruitpunch - 4,328 - - - - 4,328 17,351 25% 74,840 115,065 65%

Fruitamin Grape 34,444 24,527 - - - - 58,971 56,102 105% 380,160 347,733 109%

Fruitamin Cocobit Lychee 60,651 83,847 - - - - 144,498 87,191 166% 880,115 588,573 150%

Fruitamin Bulir Jeruk - - - - - - - 50,958 0% 24,979 337,721 7%

Fruitamin Guava 33,772 16,171 - - - - 49,943 98,279 51% 382,015 643,771 59%

Fruitamin Melon 60,298 34,575 - - - - 94,873 109,865 86% 555,319 719,302 77%

Tekita Original 171,336 140,931 - - - - 312,267 312,170 100% 2,244,915 2,218,612 101%

Tekita Apple 9,200 4,174 - - - - 13,374 20,688 65% 102,737 143,184 72%
Tekita Green 94,088 269,536 - - - - 363,624 270,069 135% 1,974,180 1,856,755 106%

Tekita Jasmine 35,220 148,242 - - - - 183,462 66,842 274% 952,328 447,271 213%

Fruitamin Cocobit Kelapa Muda 80,527 98,589 - - - - 179,116 132,541 135% 395,985 417,018 95%

Tekita Original 240 ml 29,949 55,519 - - - - 85,468 - #DIV/0! 292,006 - #DIV/0!

Tekita Green 240 ml 964 32,389 - - - - 33,353 - #DIV/0! 236,598 - #DIV/0!

TOTAL Cup 879,663 1,417,122 223,500 41,765 71,858 35,014 2,668,922 2,837,662 94% 17,262,416 19,074,190 91%

- CSD PET

P. Cola 0.5 l - - - - - - - 5,179 0% 20,621 24,115 86%

P. Twist 0.5 l - - - - - - - 1,278 0% 7,519 5,416 139%

 Jul-13 TOTAL YTD

Bukit Indah Babadan Gresik Makassar Palembang Manado TOTAL AOP target Remark TOTAL AOP target Remark

P. Blue 0.5 l 42,303 - - - - - 42,303 83,247 51% 334,015 376,273 89%

7 Up 0.5 l 1,671 - - - - - 1,671 5,849 29% 26,294 24,557 107%

Mir. Strawberry 0.5 l - - - - - - - 3,882 0% 5,893 16,081 37%

Mir. Rootberry 0.5 l 7,106 - - - - - 7,106 - #DIV/0! 39,795 - #DIV/0!

P. Cola 1.5 l 20,340 - - - - - 20,340 34,494 59% 129,151 151,430 85%

P. Twist 1.5 l 2,166 - - - - - 2,166 8,764 25% 35,144 35,820 98%

P. Blue 1.5 l 45,733 - - - - - 45,733 53,389 86% 197,830 227,038 87%

7 Up 1.5 l 3,895 - - - - - 3,895 3,975 98% 31,449 17,697 178%

Mir. Strawberry 1.5 l 1,056 - - - - - 1,056 2,208 48% 16,086 9,529 169%
TOTAL CSD PET 124,270 - - - - - 124,270 202,265 61% 843,797 887,956 95%

- CSD Can

P. Cola 34,652 - - - - - 34,652 27,435 126% 161,296 165,549 97%

P. Twist 1,203 - - - - - 1,203 1,225 98% 4,747 5,024 94%

P. Blue 18,927 - - - - - 18,927 18,258 104% 68,036 82,774 82%

7 Up 4,473 - - - - - 4,473 12,353 36% 56,237 56,101 100%

Mir. Strawberry 1,149 - - - - - 1,149 2,022 57% 12,057 12,703 95%

TOTAL CSD Can 60,404 - - - - - 60,404 61,293 99% 302,373 322,151 94%

- CSD PX&BIB

P. Cola 25,182 - - - - - 25,182 17,896 141% 127,915 122,107 105%

P. Blue 719 - - - - - 719 239 301% 5,832 1,695 344%

7 Up 2,556 - - - - - 2,556 1,123 228% 12,255 7,766 158%

Mir. Strawberry 3,622 - - - - - 3,622 2,419 150% 18,300 16,191 113%

Mir. Rootberry 431 - - - - - 431 424 102% 1,505 2,884 52%

 Jul-13 TOTAL YTD

Bukit Indah Babadan Gresik Makassar Palembang Manado TOTAL AOP target Remark TOTAL AOP target Remark

Mountain Dew 360 - - - - - 360 - #DIV/0! 600 - #DIV/0!

F. Melon - 25 - - - - 25 - #DIV/0! 114 - #DIV/0!

F. Cotton Candy 72 - - - - - 72 - #DIV/0! 1,337 - #DIV/0!

F. Bubble Gum 271 - - - - - 271 46 589% 1,805 369 489%

F. Kelapa Muda 135 - - - - - 135 - #DIV/0! 314 - #DIV/0!

TOTAL PX & BIB 33,348 25 - - - - 33,373 22,147 151% 170,554 151,012 113%

TOTAL HF PET (Gatorade) - - - - - - - - #DIV/0! 88,984 - #DIV/0!

- HF PET TROPICANA Twister

Tropicana Twister Orange 0.35 l 28,897 - - - - - 28,897 43,004 67% 112,776 235,210 48%

Tropicana Twister Apple 0.35 l 2,234 - - - - - 2,234 21,075 11% 30,938 115,271 27%

Tropicana Twister Orange 0.24 l 12,348 - - - - - 12,348 1,657 745% 56,712 9,063 626%

TOTAL HF PET TROP TWISTER 43,479 - - - - - 43,479 65,736 66% 200,426 359,544 56%

GRAND T O T A L 1,141,164 1,417,147 223,500 41,765 71,858 35,014 2,930,448 3,189,103 92% 18,868,550 20,794,853 91%
1.2 Delivery Planning - Actual vs Target
1.3 Stock Coverage of Finished Good

PO RECEIVED VS DELIVERY (July 2013) (in Raw Cases)

Shipment/ (Kurang) / Ending Stock Stock

CUP 200ML PO Received
Lebih Kirim Coverage
Delivery BIC Babadan Subcont Total

F. Orange 48,270 36,084 (12,186) 14,764 2,178 - 16,942 14

F. Strawberry 1,251,467 979,061 (272,406) 93,445 33,937 124,743 252,125 8
F. Blueberry 42,590 30,202 (12,388) 19,199 52 - 19,251 19
F. Fruitpunch 22,759 17,362 (5,397) 2,773 983 - 3,756 6
F. CocoBit 149,129 124,700 (24,429) 11,147 4,036 - 15,183 4
F. CocoBit Es Kelapa Muda 175,695 147,255 (28,440) 15,030 6,633 - 21,663 4
Grape 74,418 60,981 (13,437) 21,097 1,067 - 22,164 11
F. Gva 69,323 52,864 (16,459) 20,438 1,676 - 22,114 13
F. Mln 85,928 72,082 (13,846) 24,320 1,809 - 26,129 11
Total Fruitamin 200ml 1,945,472 1,520,591 (424,881) 222,223 52,371 124,743 399,337 8
Tekita Reguler 366,430 319,424 (47,006) 136,818 2,462 - 139,280 13
Tekita Apple 16,496 12,668 (3,828) 4,108 732 - 4,840 11
Tekita Jasmin 197,000 163,866 (33,134) 22,932 1,711 - 24,643 5
Tekita Green Tea 396,792 312,207 (84,585) 93,820 15,936 - 109,756 11
Total Tekita 200ml 976,718 808,165 (168,553) 257,678 20,841 - 278,519 10
Tekita Reguler 87,965 50,281 (37,684) 39,857 1,885 - 41,742 25
Tekita Green Tea 78,525 41,641 (36,884) 30,143 3,814 - 33,957 24
Total Tekita 240ml 166,490 91,922 (74,568) 70,000 5,699 - 75,699 25
TOTAL CUP 200ML 2,922,190 2,328,756 (593,434) 479,901 73,212 124,743 677,856 9
TOTAL CUP 240ML 166,490 91,922 (74,568) 70,000 5,699 - 75,699 25
GRAND TOTAL CUP 3,088,680 2,420,678 (668,002) 549,901 78,911 124,743 753,555 9
(in Raw Cases)
Shipment/ (Kurang) / Ending Stock Stock
CSD PET PO Received
Delivery Lebih Kirim BIC Babadan Subcont Total Coverage
Pepsi Cola 6,424 4,102 (2,322) 54 - - 54 0
Pepsi Twist 2,475 947 (1,528) - - - - -
Pepsi Blue 63,693 42,924 (20,769) 194 - - 194 0
7 Up 4,756 2,716 (2,040) 2 - - 2 0
Mirinda Strawberry 2,316 526 (1,790) 1 - - 1 0
Mirinda Rootberry 14,948 11,227 (3,721) 367 - - 367 1
Total PET 0.5 L 94,612 62,442 (32,170) 618 - - 618 0
Pepsi Cola 42,399 22,777 (19,622) 191 100 - 291 0
Pepsi Twist 16,950 7,290 (9,660) 1,297 - - 1,297 5
Pepsi Blue 58,375 40,658 (17,717) 11,677 - - 11,677 9
7 Up 9,144 7,807 (1,337) 2,308 - - 2,308 9
Mirinda Strawberry 4,522 2,589 (1,933) 1,057 - - 1,057 12
Total PET 1.5 L 131,391 81,122 (50,269) 16,530 100 - 16,630 6
(in Raw Cases)
Shipment/ (Kurang) / Ending Stock Stock
CAN PO Received
Delivery Lebih Kirim BIC Babadan Subcont Total Coverage
Pepsi Cola 33,580 32,814 (766) 229 280 - 509 0
Pepsi Twist 1,342 666 (676) 2,039 - - 2,039 92
Pepsi Blue 17,753 13,377 (4,376) 3,770 - - 3,770 8
7 Up 14,786 13,609 (1,177) 45 72 - 117 0
Mirinda Strawberry 2,267 1,898 (369) 2,123 150 - 2,273 36
Total Can 69,728 62,364 (7,364) 8,206 502 - 8,708 4
(in Raw Cases)
Shipment/ (Kurang) / Ending Stock Stock
BIB, PX, PREMIX PO Received
Delivery Lebih Kirim BIC Babadan Subcont Total Coverage

Pepsi Cola 26,088 26,088 - 1,503 405 - 1,908 2

Pepsi Blue 848 848 - 260 95 - 355 13
7 Up 1,716 1,716 - 1,474 100 - 1,574 28
Mirinda Strawberry 3,063 3,063 - 1,091 104 - 1,195 12
Mirinda Rootberry 311 311 - 296 2 - 298 29
Mountain Dew - - - 360 - - 360 -
Slurp Buble Gum 215 215 - 146 - - 146 20
Carton Candy 129 129 - 73 - - 73 17
TOTAL BIB 32,370 32,370 - 5,203 706 - 5,909 5
(in Raw Cases)
Shipment/ (Kurang) / Ending Stock Stock
GATORADE 500 ML PO Received
Delivery Lebih Kirim BIC Babadan Subcont Total Coverage
GLL 12,000 12,000 - 9,610 - - 9,610 24
GGF 12,000 12,000 - 1,378 - - 1,378 3
GOR ICE 12,000 12,000 - 10,509 - - 10,509 26
Total GATORADE 500 ML 36,000 36,000 - 21,497 - - 21,497 18
(in Raw Cases)
Shipment/ (Kurang) / Ending Stock Stock
PET 350ML PO Received
Delivery Lebih Kirim BIC Babadan Subcont Total Coverage
Twister Apl 6,801 5,525 (1,276) 994 - - 994 5
Twister Org 30,713 21,862 (8,851) 6,521 - - 6,521 9
Total PET 350ML 37,514 27,387 (10,127) 7,515 - - 7,515 8
(in Raw Cases)
Shipment/ (Kurang) / Ending Stock Stock
PET 240ML PO Received
Lebih Kirim Coverage
 (Kurang) / Stock
PET 240ML PO Received
Delivery Lebih Kirim BIC Babadan Subcont Total Coverage
Twister Org 7,862 7,716 (146) 4,622 - - 4,622 18
Total PET 240ML 7,862 7,716 (146) 4,622 - - 4,622 18
2.1 Production Cost - Actual vs Target

Trend Unit Cost FG (Production) 2013

2013
Item No. Description July Remarks
Standard Actual Variance %
1E005 TEKITA - CUP 200 ML 10,221.35 10,071.08 (150.27) (1.47)
1E007 TEKITA APPLE CUP 200 ML 9,550.75 10,275.03 724.28 7.58
1E008 TEKITA GREEN TEA CUP 200 ML 10,421.22 10,370.55 (50.67) (0.49)
1.00E+15 TEKITA JASMINE CUP 190 ML 10,505.46 10,596.39 90.93 0.87
1.00E+17 TEKITA GREEN TEA CUP 240ML 10,599.95 12,228.20 1,628.25 15.36
1.00E+19 TEKITA ORIGINAL CUP 240ML 10,323.24 11,263.78 940.54 9.11
1F002 FRUITAMIN STRAWBERRY CUP 200ML 8,430.90 9,021.92 591.02 7.01
1F004 FRUITAMIN ORANGE CUP 200 ML 8,390.72 8,849.24 458.51 5.46
1F005 FRUITAMIN BLUEBERRY CUP 200ML 8,646.35 9,466.24 819.89 9.48
1F018 FRUITAMIN JAMBU CUP 200ML 8,889.18 9,468.94 579.76 6.52
1F019 FRUITAMIN MELON CUP 200ML 8,708.43 9,059.76 351.33 4.03
1F022 FRUITAMIN COCOBIT LYCHEE CUP 180ML 8,609.83 8,833.70 223.87 2.60
1F030 FRUITAMIN COCO KELAPA MUDA CUP 180ML 7,906.37 8,432.68 526.30 6.66
Averages Cups
1A007 PEPSI CAN 330 ML 40,777.62 42,173.96 1,396.34 3.42
1A009 PC TWIST DOUBLE SHOT CAN 330ML 40,667.90 42,546.28 1,878.38 4.62
1A011 PEPSI BLUE CAN 330 ML 40,698.64 42,499.37 1,800.73 4.42
1B008 SEVEN UP EMERALD CAN 330 ML 40,886.95 41,623.62 736.67 1.80
1C008 MIRINDA STRAWBERRY CAN 330 ML 42,653.35 45,361.25 2,707.90 6.35
Averages Can
1A024 PEPSI BLUE PET 500 ML 49,937.99 48,928.73 (1,009.26) (2.02)
1B013 SEVEN UP EMERALD PET 500 ML 46,494.71 49,253.76 2,759.04 5.93
1C019 MIRINDA STRAWBERRY PET 500 ML
1C030 MIRINDA ROOTBERRY PET 500ML 48,225.63 51,817.00 3,591.37 7.45
Averages PET 500ML
1A026 PEPSI COLA PET 1500 ML 56,551.32 55,186.66 (1,364.67) (2.41)
1A028 PC TWIST DOUBLE SHOT PET1500ML 56,333.06 56,003.20 (329.86) (0.59)
1A029 PEPSI BLUE PET 1500 ML 56,373.32 54,734.79 (1,638.53) (2.91)
1B015 SEVEN UP EMERALD PET 1500 ML 54,427.23 54,829.14 401.91 0.74
1C022 MIRINDA STRAWBERRY PET 1500 ML 60,806.95 61,350.84 543.89 0.89
Averages PET 1500ML
1A016 PEPSI BIB 238,937.29 227,210.71 (11,726.58) (4.91)
1A019 PEPSI BLUE BIB 237,970.78 217,966.12 (20,004.65) (8.41)
1B011 SEVEN UP EMERALD BIB 240,647.85 226,917.43 (13,730.42) (5.71)
1C015 MIRINDA STRAWBERRY BIB 225,017.44 213,115.77 (11,901.67) (5.29)
1C016 MIRINDA ROOTBERRY BIB 217,587.82 211,966.41 (5,621.42) (2.58)
1D003 MOUNTAIN DEW BIB 248,693.22 238,148.85 (10,544.37) (4.24)
1F029 FRUITAMIN COTTON CANDY BIB 148,472.88 150,529.40 2,056.52 1.39
1F031 FRUITAMIN KELAPA MUDA BIB 115,720.49 133,675.81 17,955.32 15.52
1J005 SLURP BUBLE GUM BIB 126,230.84 128,498.92 2,268.08 1.80
Averages BIB
1I003 TWISTER ORANGE PET 240 ML 50,939.85 52,737.45 1,797.61 3.53
Averages PET 240 ML
1I001 TWISTER ORANGE PET 350ML 65,744.63 68,395.61 2,650.98 4.03
1I002 TWISTER APPLE PET 350ML 59,982.38 64,502.33 4,519.95 7.54
Averages PET 350ML
Averages Gatorade PET 500ML
GRAND TOTAL
2.2 Inventory Write Off

BS By Packing Type
Packing JULI YTD 2013
Product Name
Type Quantity Actual Cost Quantity Actual Cost
CU-TEA CUP - TEKITA 9,093.76 90,999,927.43 53,897.46 527,706,617.52
CU-FRU CUP FRUITAMIN 10,067.13 91,761,814.44 79,683.59 731,331,175.82
CA-CSD CANNING 1,151.04 49,336,309.90 4,047.21 172,961,111.76
PE-CSD PET - CSD 8,132.75 439,086,321.37 43,311.84 2,337,898,203.32
PE-TWIST PET - TWISTER 4,349.26 283,783,423.01 37,090.78 2,434,307,445.61
PE-GAT PET - GATORADE 1.25 78,006.81 174.94 9,154,140.75
PW-FRU POWDER 2,563.22 174,109,202.33 9,160.81 629,687,673.06
GRAND TOTAL 26,265.40 1,038,167,098.66 173,476.00 6,315,450,252.68

BS By Packaging
Packing JULI YTD 2013
Product Group
Type Quantity Actual Cost Quantity Actual Cost
CUP CUP 19,160.89 182,761,741.87 133,581.05 1,259,037,793.34
CAN CANNING 1,151.04 49,336,309.90 4,052.21 173,181,904.21
PET PET 500 2,337.00 117,664,238.75 15,507.83 795,293,261.56
PET 1500 5,787.33 321,090,097.12 27,537.16 1,532,030,611.92
PET 240 581.21 30,581,354.38 2,232.56 118,498,789.14
PET 350 3,768.80 253,214,089.43 34,999.45 2,322,542,472.62
PWD POWDER 2,563.22 174,109,202.33 9,160.81 629,687,673.06
GRAND TOTAL 35,359.16 1,129,167,026.09 227,373.47 6,843,156,870.20
2.3 Cost Reduction Program
3.1 KPI : Line Efficiency, Yield/Losses, Productivity

3.1.1 Efficiency
Actual
Production Line
Jan Feb Mar Apr May Jun YTD Target
CUP BIC 102.27% 97.66% 92.00% 100.23% 93.52% 90.07% 94.36% 95.00%
CUP BBD 96.91% 92.43% 92.52% 89.39% 92.02% 93.66% 92.70% 95.00%
CSD CAN 72.07% 59.25% 70.71% 67.41% 64.27% 60.18% 65.47% 65.00%
CSD PET 72.05% 75.36% 73.20% 80.01% 80.29% 82.33% 77.98% 80.00%
CSD BIB 94.77% 93.67% 97.15% 99.54% 100.03% 99.09% 97.47% 95.00%
HF TROPICANA 53.53% 51.90% 51.09% 59.32% 59.82% 61.33% 55.32% 70.00%
HF (GATORADE) 30.43% 42.55% 52.21% 43.81% 65.00%
Total Line EFF (BIC) 93.56% 81.66% 87.67% 91.69% 86.35% 86.38% 86.54% 90.00%

3.1.2 Losess and Variance

Losses
BIC Usage Theoritical Losses Losses (%) Losses (Rp) (Cost/cs)

Packaging (pcs) 76,617,144 76,232,217 384,927 0.50% 66,090,161 43

CO2 (kg) 81,342 60,502 20,840 25.62% 43,763,626 184

Sugar & HFCS (kg) 1,171,155 1,154,284 16,871 1.44% 124,344,810 81

Concentrate (Unit) 4,526 4,417 110 2.42% 193,985,875 126

Total Plant Waste 428,184,472 #DIV/0!

* packaging include carton, bottle,closure,label,sleeve,cup,lid,can,endroll,syrup bag

Losses
BBD Usage Theoritical Losses Losses (%) Losses (Rp) (Cost/cs)

Packaging (pcs) 80,043,135 79,704,233 338,902 0.42% 49,321,200 30.32

Sugar & HFCS (kg) 573,261 559,485 13,776 2.40% 107,071,298 65.82

Concentrate (Unit) 4,714 4,610 104 2.21% 60,293,792 37.07

Total Plant Waste 216,686,290 133.21

* packaging include carton, cup, lid

3.1.3 Productivity Calculation
Line NCP Tot Man Hrs Productivity

CUP 1,198,764.00 56,075.43 21.38

CSD CAN 28,475.00 1,739.87 16.37

CSD PET 208,085.00 17,899.89 11.62

BIB 26,607.00 2,751.25 9.67

HF PET 75,983.00 7,954.56 9.55

1,537,914.00 86,421.00 17.80

Tot man hrs involving performer hrs + admin&management hrs (incl. OT)
3.2 ENERGY USAGE

KWH/Lt Beverage AOP TARGET YTD BIC 2012 YTD BBD 2012 YTD BIC 2013 YTD BBD 2013 Des'12 Jan Feb Mar Apr May Jun Jul Aug Sep Okt Nov Dec
ENERGY USAGE 0.150 0.105 0.152 0.117 0.206 Bulan jam kerja
BIC 0.100 0.104 0.135 0.109 0.109 0.121 0.123 Apr 465
BBD 0.152 0.173 0.167 0.206 0.199 0.174 0.170 May 465
Dec 570

1500
0.2

0.16

0.12

0.08

0.04

0
YTD BBD 2012

YTD BBD 2013

Des'12

May

Nov

Dec
Okt
Mar
YTD BIC 2012

YTD BIC 2013

AOP TARGET

Jan

Feb

Jun

Aug

Sep
Apr

Jul
Jan Feb Mar Apr May Jun Jul Aug Sep Okt Nov Dec
Usage Solar 13,673.88 14,686.76 17,483.69 17,230.47 16,194.57 19,100.15
Usage LNG 464,673.18 605,023.62 798,041.85 710,600.10 772,988.38 1,406,215.23
Usage Elektric 127,690.00 171,020.00 131,817.00 113,112.00 122,471.00 176,568.00
Total energy 606,037.06 790,730.38 947,342.54 840,942.57 911,653.95 1,601,883.38 0.00 0.00 0.00 0.00 0.00 0.00
Litr Beverages 5,841,890.04 5,856,633.48 8,699,259.00 7,695,479.00 7,549,726.08 13,074,845.64 0.00 0.00 0.00 0.00 0.00 0.00
Energy Usage 0.104 0.135 0.109 0.109 0.121 0.123 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Ytd Usage Solar 13,673.88 28,360.64 45,844.33 63,074.80 79,269.37 98,369.52 98,369.52 98,369.52 98,369.52 98,369.52 98,369.52 98,369.52
Ytd Usage LNG 464,673.18 1,069,696.80 1,867,738.65 2,578,338.75 3,351,327.13 4,757,542.36 4,757,542.36 4,757,542.36 4,757,542.36 4,757,542.36 4,757,542.36 4,757,542.36
Ytd Usage Elektric 127,690.00 298,710.00 430,527.00 543,639.00 666,110.00 842,678.00 842,678.00 842,678.00 842,678.00 842,678.00 842,678.00 842,678.00
Ytd Total energy 606,037.06 1,396,767.44 2,344,109.98 3,185,052.55 4,096,706.50 5,698,589.88 5,698,589.88 5,698,589.88 5,698,589.88 5,698,589.88 5,698,589.88 5,698,589.88
Ytd Litr Beverages 5,841,890.04 11,698,523.52 20,397,782.52 28,093,261.52 35,642,987.60 48,717,833.24 48,717,833.24 48,717,833.24 48,717,833.24 48,717,833.24 48,717,833.24 48,717,833.24
Ytd Energy Usage 0.104 0.119 0.115 0.113 0.115 0.117 0.117 0.117 0.117 0.117 0.117 0.117
3.3 WATER CONSERVATION

Lt/Lt Beverage AOP TARGET YTD BIC 2012YTD BBD 2012YTD BIC 2013YTD BBD 2013 Des'12 Jan Feb Mar Apr May Jun Jul Aug Sep Okt Nov Dec
WATER CONSERVATION 1 1.228 1.33 1.465 1.34 Bulan jam kerja
BIC 1.069 1.284 1.715 1.156 1.398 1.513 1.653 Apr 465
BBD 1.330 1.450 1.480 1.900 1.550 1.800 1.680 May 465
Dec 570

1500
3

2.5

1.5

0.5

0
YTD BBD 2013

May

Okt
YTD BIC 2012

YTD BBD 2012

YTD BIC 2013

Des'12

Nov

Dec
Jan

Feb

Jun

Aug

Sep
Mar

Apr
AOP TARGET

Jul
Jan Feb Mar Apr May Jun Jul Aug Sep Okt Nov Dec
Gross Water 13,343,000 15,899,000 18,756,000 18,450,000 18,973,000 34,689,000
Theoritical Water 5,841,890 5,856,633 8,699,259 7,695,479 7,549,726 13,074,846
Total 7,501,110 10,042,367 10,056,741 10,754,521 11,423,274 21,614,154 0 0 0 0 0 0
Water Conservation 1.284 1.715 1.156 1.398 1.513 1.653 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Ytd Gross Water 13,343,000 29,242,000 47,998,000 66,448,000 85,421,000 120,110,000 120,110,000 120,110,000 120,110,000 120,110,000 120,110,000 120,110,000
Ytd theoritical water 5,841,890 11,698,524 20,397,783 28,093,262 35,642,988 48,717,833 48,717,833 48,717,833 48,717,833 48,717,833 48,717,833 48,717,833
Ytd Total 7,501,110 17,543,476 27,600,217 38,354,738 49,778,012 71,392,167 71,392,167 71,392,167 71,392,167 71,392,167 71,392,167 71,392,167
Ytd Water Conservation 1.284 1.500 1.353 1.365 1.397 1.465 1.465 1.465 1.465 1.465 1.465 1.465
3.4 Serious Trouble

MONTHLY MECHANICAL DOWNTIME REPORT

Jul-13

CUP Line 1

Mech. DT Trouble Description Corrective Action ME Long Term Solution

NO Area MD
HOUR FREQ

Temprature of produck not stable,

1 Preparation 4.17 9
transfer pump problem
2 Video Jet 3.26 7 Printing not clear, dirt and NG
3 Packer 1.83 11 Bast pack machine problem
4 Filler 1.50 3 Correcting plate out of set
5 Triming 0.92 2

CUP Line 2

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO Area
HOUR FREQ

Teflon sheet out of seting, can not reach

1 Heater 4.25 9 themperature, A3, A4 block problem,
mounting A8 block broken
Out feed filler conveyor broken, Packer
2 Conveyor 3.34 6
konveyor jam
Printing dinot clear, nozle block, box
3 Video Jet 2.26 6
printer problem
4 Packer 1.86 9 Bast pack machine Problem
5 Preparation 1.00 2 Themperature not stable

CUP Line 4

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO Area
HOUR FREQ
1 Video jet 3.99 6 Nozle dirt and printing quality NG
 Filling valve problrm, out feed chain
drive broken, roll lid breake spring
2 Filler 2.84 7 broken
3 Heater 1.75 3 B7 Block over heat, welding in line 2
4 Supply cup 1.75 4 Cup feeder broken
5 Preparation 1.33 3 Cooling system problem

CUP Line 5

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO Area
HOUR FREQ
Strainer , filter block, outomatic for
1 Preparation 5.93 18 supply syrup not working,
Heater block problem, thermocouple
2 Filler 2.35 6 wire loos
3 Warmer 0.5 1 Belt of the tapping machine broken
4 Triming 0.5 1
Heater block laction B3 temprature too
5 Heater 0.34 2 low

CUP Line 6

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO DESCRIPTION
HOUR FREQ
WKT FREQ
1 Preparation 4.17 14 Strainer block
2 Heater 2.84 3 Heater block problem
Printing result not good, printing head
3 Video Jet 0.75 4 dirt, error code block
4 Packer 0.17 1 Tapping machine setting problem
5 Utility 0.17 1 Air pressure drop

CAN Line

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO DESCRIPTION
HOUR FREQ
 1 Seamer 8.85 16 Can deform too many
2 Filler 6.69 21 Piston seal problem fon many station
3 Conveyor 2.2 3 Depalletise conveyor jam
4 Packer 1.45 8 Packer problem
Printing result not good, printing head
dirt, error code block, un stable air
5 Video Jet 1.25 2 presure

PET 500 ml

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO DESCRIPTION
HOUR FREQ
Trouble labeller (setting dudukan sensor,
motor feed roll error, lem tidak sempurna
nempelnya sering miring, & label setting se max. mungkin. Spare part ring
1 Labeler 16.27 79 nyangkut di kawat glue roll) teflon belum datang
Trouble filler (rante kendor, cek piston
2 Rinser 0.83 4 baut yang kendor)
Starwheel outfeed out of setting, Chain
3 Filler 0.75 2 tension loos
4
5

PET 1500 ml

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO DESCRIPTION
HOUR FREQ
Trouble labeller (vacum drum kotor,
sering aplication & label sering tidak
1 Labeler 29.44 55 nempel )
Trouble conveyor (conveyor mendadak
berhenti, problem conveyor inveed
2 Conveyor 3.78 5 warmer & conveyor sering ngetrip)
Trouble filler (piston tidak naik-naik &
ganti seal piston no 34 bocor, ganti
3 Filler 3.19 10 ventube low & high level)
4 Packer 1.71 3 Drive belt conveyor short circuit
5 Caper 1.24 6 Torque problem
HF Gatorade 500 ml

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO DESCRIPTION
HOUR FREQ
1
2
3
4
5

HF Tropicana 350 ml

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO DESCRIPTION
HOUR FREQ
1 Filler 1.12 2 filler problem
2 Depalletiser 0.59 3 Depalletiser problem
3 Labeler 0.25 1 Labeler problem
4
5

HF Tropicana 240 ml

TOTAL Trouble Description Corrective Action ME Long Term Solution

NO DESCRIPTION
HOUR FREQ
1 Labeler 3.88 9 sensor Mounting NG
2 Filler 2.55 2
3 Video Jet 1.67 2
4 Depalletiser 1.23 5
5 HTST 0.52 2 Steam motor tripped
3.5 Project Improvement

No Project Name Project description Status Purpose Target Plan

1 Fruitamin Preparation 1.Civil Working for additional area : Mixing Syrup preparation for Fruitamin
2 x 15.000 L Tank Delivery material & Parts Oct-13
2.High shear
mixer Tank
2 New UHT PHE Unit Replacing the manual old PHE unit with the - Automation of Tea Pasteurisation -
new one Done Improving performance quality of tea Product Feb-13

3 Revision of Relocate Opp
Labeller
4 Truck Scale
5 Load cell HFCS Container
6 Depalletizer HF PET Line
Additional 3 meters single conveyor at Still many bottle fall when bottle out from buffer
Done Jan-13
infeed opp labeller table modular.
1.Civil foundation of load cell platform Controlling & monitoring of Truck that will be
Done Feb-13
2.Control room building loading / unloading
Install load cell in every container Monitoring and recording the HFCS used by
Done Feb-13
Install Monitor & PC PC at WH office
1.Cost Benefit Analysis -Reducing downtime in Twister & Gatorade
2. Replacement the existing manual Pending Production
depalletizer with the new auto depalletizer. (CEA Progress stuck at Pending
BOD)

7 Upgrade AHU Filler cup 1 - 4 1. Additional Chiller unit on the existing AHU Pending Reducing the Micro risk Contamination from
( CEA Progress sweating and allowing ambient temperature Pending
stuck at BOD) room at + 26 ºc ( Room Temperature Existing
8 Improvement cooling Tunnel 1. Spray Performance Upgrading and + 50 ºC.) the performance to decreasing of
Upgrading
Done 2013
cup 5 & 6 improvement of media cooling system the tea product temperature.
9 CSD Can Fill+Seamer 1. New Filling and seaming machine Improvisation of performance yield of CSD
replacement 2. ME & Civil work of Are being estimated Canning line productivity, Minimalisation of 2013
utilization breakdown in the line and upgrade the quality
10 Temporary Warehouse tent accommodating the Gatorade & CSD of
FGthe product.
Product covered from the Sun and Rainy
product during incubating time . Done Jun-13

11 Install Bag Filter at Sugar Replacing the manual filter press Reducing of Filter media usage quantity, No
Dissolving Done leaks on filter, More Hygine and Raising up the 2013
accelerate of production time .
12 Inplant Blowing on CSD PET 1. Additional new blowing PET machine. Improvisation of performance yield of CSD
2. Additional new PET line productivity, Raising up the
way of air conveyor Are being estimated accelerate of production time and upgrade the 2013
3. ME & civil work of utilization quality of the product.
4.1. Product Quality

4.1.1 Fruitamin Cup

CUP - FRUITAMIN Strawberry July 2013 CUP - COCOBIT Leci July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 6.5 - 6.7 % 131 6.57 6.62 6.70 100 Brix 4.0 - 4.2 % 63 4.12 4.08 4.16 100
pH 3.00 - 3.60 131 3.35 3.3 3.45 100 pH 4.00 - 4.40 63 4.20 4.14 4.36 100
TA 25.0 - 29.0 40 27 25.6 28.4 100 TA 15.0 - 19.0 21 17.6 16.4 18.6 100
Aciduric Bactery 30 CFU/100ml 40 0.05 0 2 100 Aciduric Bactery 30 CFU/100ml 21 0 0 0 100
Yeast 10 CFU/100ml 40 0 0 0 100 Yeast 10 CFU/100ml 21 0 0 0 100
Mould 10 CFU/100ml 40 0 0 0 100 Mould 10 CFU/100ml 21 0 0 0 100

CUP - FRUITAMIN Anggur July 2013 CUP - COCOBIT Kelapa Muda July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 5.2 -5.4 % 8 5.28 5.22 5.35 100 Brix 5.0 -5.2 % 52 5.13 5.02 5.15 100
pH 3.10 - 3.50 8 3.32 3.25 3.47 100 pH 4.10 - 4.30 52 4.22 4.15 4.27 100
TA 32.0 - 36.0 2 34 32.5 35.5 100 TA 10.0 - 12.0 18 11.4 10.3 11.8 100
Aciduric Bactery 30 CFU/100ml 2 0 0 0 100 Aciduric Bactery 30 CFU/100ml 18 0 0 0 100
Yeast 10 CFU/100ml 2 0 0 0 100 Yeast 10 CFU/100ml 18 0 0 0 100
Mould 10 CFU/100ml 2 0 0 0 100 Mould 10 CFU/100ml 18 0 0 0 100

CUP - FRUITAMIN Orange July 2013

Standard n avg min max % In-spec Checking Frequency
Brix 5.3 -5.5 % 23 5.40 5.35 5.44 100 Brix Every 30 min
pH 3.20 - 4.00 23 3.42 3.23 3.53 100 pH Every 30 min
TA 29.5 - 33.5 6 31.6 30.8 32 100 TA Every batch
Aciduric Bactery 30 CFU/100ml 6 0 0 0 100 Aciduric Bactery Every day production
Yeast 10 CFU/100ml 6 0 0 0 100 Yeast Every day production
Mould 10 CFU/100ml 6 0 0 0 100 Mould Every day production

CUP - FRUITAMIN Blueberry July 2013

Standard n avg min max % In-spec
Brix 4.9 - 5.1 %
pH 3.25 - 3.65
TA 29.0 - 33.0
Aciduric Bactery 30 CFU/100ml
Yeast 10 CFU/100ml
Mould 10 CFU/100ml

CUP - FRUITAMIN Jambu July 2013

Standard n avg min max % In-spec
Brix 4.7 - 4.9 %
pH 3.70 - 4.10
TA 22.5 - 26.5
Aciduric Bactery 30 CFU/100ml
Yeast 10 CFU/100ml
Mould 10 CFU/100ml

CUP - FRUITAMIN Melon July 2013

Standard n avg min max % In-spec
Brix 4.8 - 5.0 %
pH 4.60 - 6.40
TA 1.0 - 3.0
Aciduric Bactery 30 CFU/100ml
Yeast 10 CFU/100ml
Mould 10 CFU/100ml

CUP - FRUITAMIN Fruitpunch July 2013

Standard n avg min max % In-spec
Brix 4.8 - 5.0 %
pH 3.40 - 4.20
TA 16.5 - 20.5
Aciduric Bactery 30 CFU/100ml
Yeast 10 CFU/100ml
Mould 10 CFU/100ml

4.1.2 Tekita Cup

CUP - TEKITA Original July 2013 CUP - TEKITA Jasmine July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 8.1 - 8.3 % Brix 8.5 - 8.7 %
pH 5.30 - 6.00 pH 5.30 - 6.00
Tannin 49.0 - 51.0 mg/100 ml Tannin 30.0 - 32.0 mg/100 ml
Bactery 20 CFU/100ml 90 0 0 2 100 Bactery 20 CFU/100ml 36 0 0 0 100
Yeast 5 CFU/100ml 90 0 0 0 100 Yeast 5 CFU/100ml 36 0 0 0 100
Mould 5 CFU/100ml 90 0 0 0 100 Mould 5 CFU/100ml 36 0 0 0 100

CUP - TEKITA Green Tea July 2013 CUP - TEKITA Apple July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 8.4 - 8.6 % Brix 4.8 - 5.0 %
pH 5.30 - 6.00 pH 3.60 - 4.00
Tannin 38.0 - 42.0 mg/100 ml Tannin 11.0 - 13.0 mg/100 ml
Bactery 20 CFU/100ml 60 0 0 0 100 TA 21.5 - 25.5
Yeast 5 CFU/100ml 60 0 0 0 100 Aciduric Bactery 20 CFU/100ml 5 0 0 0 100
Mould 5 CFU/100ml 60 0 0 0 100 Yeast 5 CFU/100ml 5 0 0 0 100
Mould 5 CFU/100ml 5 0 0 0 100
Checking Frequency
Brix Every 30 min
pH Every 30 min
Tannin Every batch
Aciduric Bactery Every batch
Yeast Every batch
Mould Every batch

4.1.3 CSD

CAN CSD - Pepsi Cola July 2013 PET CSD - Pepsi Cola July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 10.5 - 10.9 Brix 10.5 - 10.9
CO2 3.4 - 3.8 CO2 3.8 - 4.2
pH 2.35 - 2.55 pH 2.35 - 2.55
TA 10.67 - 12.36 TA 10.67 - 12.36
Aciduric Bactery 30 CFU/100ml Aciduric Bactery 30 CFU/100ml
Yeast 15 CFU/100ml Yeast 15 CFU/100ml
Mould 15 CFU/100ml Mould 15 CFU/100ml
CAN CSD - Pepsi Blue July 2013 PET CSD - Pepsi Blue July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 10.6 - 11.0 Brix 10.6 - 11.0
CO2 3.4 - 3.8 CO2 3.8 - 4.2
pH 2.75 - 3.15 pH 2.75 - 3.15
TA 11.50 - 12.43 TA 11.50 - 12.43
Aciduric Bactery 30 CFU/100ml Aciduric Bactery 30 CFU/100ml
Yeast 15 CFU/100ml Yeast 15 CFU/100ml
Mould 15 CFU/100ml Mould 15 CFU/100ml

CAN CSD - Pepsi Twist July 2013 PET CSD - Pepsi Twist July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 10.3 - 10.7 Brix 10.3 - 10.7
CO2 3.4 - 3.8 CO2 3.8 - 4.2
pH 2.85 - 3.05 pH 2.85 - 3.05
TA 18.92 - 19.85 TA 18.92 - 19.85
Aciduric Bactery 30 CFU/100ml Aciduric Bactery 30 CFU/100ml
Yeast 15 CFU/100ml Yeast 15 CFU/100ml
Mould 15 CFU/100ml Mould 15 CFU/100ml

CAN CSD - 7 Up July 2013 PET CSD - 7 Up July 2013

Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 10.7 - 11.1 Brix 10.7 - 11.1
CO2 3.2 - 3.6 CO2 3.6 - 4.0
pH 3.15 - 3.55 pH 3.15 - 3.55
TA 24.56 - 25.49 TA 24.56 - 25.49
Aciduric Bactery 30 CFU/100ml Aciduric Bactery 30 CFU/100ml
Yeast 15 CFU/100ml Yeast 15 CFU/100ml
Mould 15 CFU/100ml Mould 15 CFU/100ml

CAN CSD - Mirinda Strawberry July 2013 PET CSD - Mirinda Strawberry July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 13.6 - 14.0 Brix 13.6 - 14.0
CO2 2.4 - 2.8 CO2 2.8 - 3.2
pH 3.05 - 3.25 pH 3.05 - 3.25
TA 11.94 - 12.85 TA 11.94 - 12.85
Aciduric Bactery 30 CFU/100ml Aciduric Bactery 30 CFU/100ml
Yeast 15 CFU/100ml Yeast 15 CFU/100ml
Mould 15 CFU/100ml Mould 15 CFU/100ml

PET CSD - Mirinda Rootberry July 2013

Checking Frequency Standard n avg min max % In-spec
Brix Every 30 min Brix 12.9 - 13.3
CO2 Every 30 min CO2 3.6 - 4.0
pH Every 30 min pH 3.25 - 3.65
TA Every batch TA 6.34 - 7.25
Aciduric Bactery Every day production Aciduric Bactery 30 CFU/100ml
Yeast Every day production Yeast 15 CFU/100ml
Mould Every day production Mould 15 CFU/100ml

4.1.4 CSD BIB

Postmix BIB - Pepsi Cola July 2013 Postmix BIB - Mirinda Strawberry July 2013
Standard (Contr n avg min max % In-spec Standard (Contro n avg min max % In-spec
Brix 10.5 - 10.9 Brix 13.6 - 14.0
pH 2.35 - 2.55 pH 3.05 - 3.25
TA 10.67 - 12.36 TA 11.94 - 12.85

Postmix BIB - Pepsi Blue July 2013 Postmix BIB - 7 Up July 2013
Standard (Contr n avg min max % In-spec Standard (Contro n avg min max % In-spec
Brix 10.6 - 11.0 Brix 10.7 - 11.1
pH 2.70 - 3.10 pH 3.15 - 3.55
TA 11.62 - 12.55 TA 24.56 - 25.49

Checking Frequency
Brix Every Batch
pH Every Batch
TA Every Batch
4.1.5 NCB

PET NCB - TROPICANA Orange July 2013 PET NCB - GATORADE Lemon Lime July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 13.8 - 14.2 Brix 6.2 - 6.6
pH 3.25 - 3.65 pH 2.70 - 3.30
TA 50.00 - 55.35 TA 47.88 - 48.84
Aciduric Bactery <1 CFU/10 ml Aciduric Bactery <1 CFU/10 ml
Yeast <1 CFU/10 ml Yeast <1 CFU/10 ml
Mould <1 CFU/10 ml Mould <1 CFU/10 ml

PET NCB - TROPICANA Apple July 2013 PET NCB - GATORADE Orange Grapefruit July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Brix 11.3 - 11.7 Brix 6.1 - 6.5
pH 2.90 - 3.30 pH 2.95 - 3.35
TA 30.3 - 33.0 TA 35.20 - 36.15
Aciduric Bactery <1 CFU/10 ml Aciduric Bactery <1 CFU/10 ml
Yeast <1 CFU/10 ml Yeast <1 CFU/10 ml
Mould <1 CFU/10 ml Mould <1 CFU/10 ml

Checking Frequency PET NCB - GATORADE Orange Ice July 2013

Brix Every 30 min Standard n avg min max % In-spec
pH Every 30 min Brix 6.2 - 6.6
TA Every batch pH 2.80 - 3.20
Aciduric Bactery Every day production TA 45.40 - 46.36
Yeast Every day production Aciduric Bactery <1 CFU/10 ml
Mould Every day production Yeast <1 CFU/10 ml
Mould <1 CFU/10 ml
4.2. Environmental Monitoring

4.2.1 Air

ENVIRONMENT - AIR : Aciduric Bactery July 2013 ENVIRONMENT - AIR : Mould July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
BIB Room < 50 CFU/100 ltr BIB Room < 50 CFU/100 ltr
Filling Ro < 50 CFU/100 ltr Filling Ro < 50 CFU/100 ltr
Filling Ro < 50 CFU/100 ltr Filling Ro < 50 CFU/100 ltr
Syrup Roo < 50 CFU/100 ltr Syrup Roo < 50 CFU/100 ltr
Batching NA Batching < 10 CFU/100 ltr
Cap Room NA Cap Room < 10 CFU/100 ltr
Rinser & F NA Rinser & F < 10 CFU/100 ltr
Under air NA Under air < 10 CFU/100 ltr
Inoculatio < 50 CFU/100 ltr Inoculatio < 50 CFU/100 ltr
Inoculatio NA Inoculatio < 5 CFU/100 ltr

ENVIRONMENT - AIR : Yeast July 2013

Standard n avg min max % In-spec Checking Frequency Checking Frequency NCB
BIB Room < 50 CFU/100 ltr Aciduric BaEvery month Every week
Filling Ro < 50 CFU/100 ltr Yeast Every month Every week
Filling Ro < 50 CFU/100 ltr Mould Every month Every week
Syrup Roo < 50 CFU/100 ltr
Batching < 10 CFU/100 ltr
Cap Room < 10 CFU/100 ltr
Rinser & F < 10 CFU/100 ltr
Under air < 10 CFU/100 ltr
Inoculatio < 50 CFU/100 ltr
Inoculatio < 5 CFU/100 ltr

4.2.2 Swab
ENVIRONMENT - SWAB : Aciduric Bactery July 2013 ENVIRONMENT - SWAB : Mould July 2013
Standard n avg min max % In-spec Standard n avg min max % In-spec
Blending < 10 CFU/swab Blending < 10 CFU/swab
Filling Val < 25 CFU/swab Filling Val < 10 CFU/swab
Blending NA Blending < 10 CFU/swab
Balance T NA Balance T < 10 CFU/swab
Filling val < 25 CFU/swab Filling val < 10 CFU/swab
Blending T NA Blending T < 10 CFU/swab
Bowl Filler NA Bowl Filler < 10 CFU/swab
Filling Val < 25 CFU/swab Filling Val < 10 CFU/swab

ENVIRONMENT - SWAB : Yeast July 2013

Standard n avg min max % In-spec Checking Frequency
Blending < 10 CFU/swab Aciduric BaEvery week
Filling Val < 10 CFU/swab Yeast Every week
Blending < 10 CFU/swab Mould Every week
Balance T < 10 CFU/swab
Filling val < 10 CFU/swab
Blending T < 10 CFU/swab
Bowl Filler < 10 CFU/swab
Filling Val < 10 CFU/swab
4.3. Water Quality

WATER July 2013

Standard n avg min max % In-spec
RAW WATER TPC 500 CFU/1 ml 4 90.5 78 121 100 Raw Water
CLTS Cl2 after Carbon negative 600 0 0 0 100 CLTS
M Alkalinity ≤ 50 ppm 300 31.4 23 39 100
TDS ≤ 500 ppm 75 128.3 118 152 100
TPC 50 CFU/1 ml 4 45 14 115 75 Replace UV Lamp on week-4
Coliform negative 4 negative negative negative negative
Reverse Osmosis pH 5-9 60 6.24 6 7.5 100 RO
M Alkalinity ≤ 50 ppm 60 5 5 5 100
Hardness ≤ 25 ppm 60 0 0 0 100
TDS ≤ 100 ppm 15 4.4 3.8 5.7 100
TPC 50 CFU/1 ml 2 38 4 72 50 Replace UV Lamp on week-2
Coliform negative 2 negative negative negative negative Checking Frequency
TPC Every week
Cl2 after Carbon Every 1 hour
M Alkalinity Every 1 hour
TDS Every shift
TPC Every week
Coliform Every week
pH Every 4 hours
M Alkalinity Every 4 hours
Hardness Every 4 hours
TDS Every 4 hours
TPC Every week
Coliform Every week
4.4. Raw and Packacing Material Quality - Supplier Performance

Material Supplier Incoming Numbers Incoming Test Note

Raw material
Pottasium Sorbat Pafa Mandiri Sakti 1 Pass Checking Frequency
Chemco Prima Mandiri 1 Pass Every incoming
EDTA Glory Katri Putra 1 Pass
Na. Citrate Dinamika Maju Usaha 1 Pass
Calcium Lactate Dinamika Maju Usaha 1 Pass
Aspartame Ajinomoto 1 Pass
Acesulfame K Chemco Prima Mandiri 1 Pass
KCL Global Chemindo Megatrading 1 Pass
Malic Acid Global Chemindo Megatrading 1 Pass
Citric Acid Global Chemindo Megatrading 1 Pass
Na. Ascorbate Satya Samitra Niagatama 1 Pass
Vitamin C Satya Samitra Niagatama 1 Pass
Sucralose Sumber Food Ingredient 1 Pass
Orange Sac Pafa Mandiri Sakti 1 Pass
Nata de Coco (Press) Daya Agro Mitra Mandiri 3 Pass
Nata de Coco (Serut) Daya Agro Mitra Mandiri 2 Pass
Sugar Sentra Usahatama Jaya 3 Pass
Permata Dunia Sukses Utama 12 Pass
Labinta 8 Pass
Jawa Manis Rafinasi 5 Pass
Teh (GTX Instant Tea 1165E48-2) Tri Raharja 1 Pass

Packaging material
Cup PP Bina Plaspac 16 Pass
Poly Unggul 7 Pass
Mitraplas 2 Pass
Lid Prima Jaya Eratama 4 Pass
Indoceria 1 Pass
ICBP 1 Pass
 Bella Prima 1 Pass
Carton Sentralindo Teguh Gemilang 10 Pass
Rapipack 5 Pass
Daya Cipta 7 Pass
Surya Rengo 1 Pass
Sedotan Straw Plus 1 Pass
Aneka Mitra Jaya 1 Pass
Can Conpac 2 Pass
Closure CSI 5 Pass
CO2 Molindo 5 Pass
Samator 4 Pass
OPP Bella Prima 1 Pass
PET CSD Sari Multi Utama 23 Pass
Indo Tirta Abadi 16 Pass
PET NCB Nobel 13 Pass
Carton Sentralindo Teguh Gemilang 18 Pass
Rapipack 5 Pass
Daya Cipta 10 Pass
4.5. Quality Issue - serious trouble

Date/Period Product Issue Analysis Corrective Action

February 2012 Tekita Defect Sensory on some production dates Leaking pHE plates Using new pHE (March 2012)
Nov 2012 - Apr 2013 Tekita Defect Sensory on some production dates Tea particle from extraction found in defect products No more tea leaves extraction
Available Filtration couldn't solve the issue Using Tea powder as RM (May2013)
4.6 Customer Complaint

Customer Date Product Brand Code Issue Analysis Corrective Action

Heat Resistant Mould type A growing
Gatorade
NCB PET 500 ml in product, temper band broken on Validation on camera
Lemon Lime
Permanis Malaysia 21 May 13 B 21:03 100312 Foreign Matter receipt performance for automatic
selector

KFC Surabaya 11 Mar 13 121213; 271213

Install air blower (28 Apr 13) to
KFC Manado 6 April 13 271213 Stress corrosion on scoring part (End
remove carryover water, located
CSD Can 330 ml Pepsi Cola Pop Up roll) due to some water drop on
KFC Banjarmasin 12 Apr 13 271213 at conveyor on the way to carton
product leaving Warmer
packer
KFC Makassar 15 May 13 270214
(Internal) 5-Jul-05 Cup 200 ml Tekita Regular BIC Defect Sensory
Extraction issue for BIC In progress
Cup 190 ml Tekita Green Tea Babadan (internal)
Tekita Jasmine Foaming issue for BIC (Tea powder)
5.1 Incident Report

Accident On June, Year 2013

Current Month Year To Date

No Departement No Of
No Of Employee
No Of Cases Loss Days No Of Cases Employee Loss Days
Suffered
Suffered

1 Production 1 1 1 2 2 2

2 ME 1 1 1 1 1 1

3 Quality Control 1 1 1

4 Warehouse FG

5 Warehouse RM

6 Warehouse Spare Part

7 Fin & Accounting

8 HRD

9 PPIIC & Purchasing

5.2 Health Report

Medical Record

No Date Department Subject Finding Action

Routine yearly
All permanent and Partner Kyoei
1 7-Jan-13 All Department medical check up
contractual employees Health Care
(period 2012)

Follow up check-
From MCU result
up and treatment
2 4-Jun-13 QC Sumarno 2012, suspect
at Medistra
Hepatitis
Hospital

Noise Record

Result Standard
No Sampling date Institution Parameter
Indoor Outdoor Indoor Outdoor

Dinas Tata Ruang &

1 11-Feb-13 Permukiman Balai Pengujian Noise 84,1 db 48,9 db 85 db 85 db
Mutu Konstruksi & Lingkungan

2
Lux Record

No Sampling date Area Lux Keterangan

Not yet carried out

 Remarks
2x per year
measurements.
Results are
reported to the
local
environmental
government
institution
5.3 Environmental Report

WWTP (Standard from BITA, COD max 900, pH : 6-10)

Sampling Date of INLET OUTLET
No. Time
date analysis pH COD pH COD
1 1-Jun-13 10:02 3-Jun-13 4.83 4224.26 6.89 55.15
2 2-Jun-13 11:15 3-Jun-13 7.38 44.12
3 3-Jun-13 14:12 6-May-13 3.96 2832.71 7.10 66.91
4 4-Jun-13 13:56 6-May-13 5.96 3234.20 7.50 89.22
5 5-Jun-13 13:00 6-May-13 8.90 4583.64 7.92 94.80
6 6-Jun-13 13:15 10-Jun-13 6.14 3494.51 7.75 329.67
7 7-Jun-13 10:33 10-Jun-13 10.57 5890.11 8.20 351.65
8 8-Jun-13 10:35 10-Jun-13 6.00 3703.30 7.97 340.66
9 9-Jun-13 13:15 10-Jun-13 4.78 4857.14 7.45 384.62
10 10-Jun-13 13:20 12-Jun-13 11.49 5701.11 7.72 254.61
11 11-Jun-13 10:25 12-Jun-13 5.20 5856.09 7.05 309.96
12 12-Jun-13 13:57 13-Jun-13 3.53 18543.44 7.82 365.99
13 13-Jun-13 13:50 13-Jun-13 3.43 44262.48 7.65 720.89
14 14-Jun-13 9:45 19-Jun-13 3.39 44173.75 7.06 865.06
15 15-Jun-13 10:17 19-Jun-13 5.38 3449.17 6.78 133.09
16 17-Jun-13 13:50 19-Jun-13 5.42 3127.54 7.24 510.17
17 18-Jun-13 10:20 19-Jun-13 5.42 3815.16 6.95 698.71
18 19-Jun-13 10:05 19-Jun-13 4.80 3138.63 7.05 609.98
19 20-Jun-13 14:15 22-Jun-13 5.85 2954.89 7.32 157.89
20 21-Jun-13 10:20 22-Jun-13 5.32 5943.61 7.48 169.17
21 22-Jun-13 10:38 22-Jun-13 5.17 5063.91 7.43 699.25
22 23-Jun-13 10:36 27-Jun-13 7.61 544.42
23 24-Jun-13 13:06 27-Jun-13 12.36 748.58 7.85 544.42
24 25-Jun-13 10:55 27-Jun-13 6.48 1667.30 7.54 328.92
25 26-Jun-13 10:02 27-Jun-13 4.48 6000.00 7.24 453.69
26 27-Jun-13 10:25 1-Jul-13 5.81 3122.22 7.33 155.56
27 28-Jun-13 10:25 1-Jul-13 4.73 2711.11 7.18 111.11
28 29-Jun-13 14:45 1-Jul-13 8.52 2266.67 7.85 11.11
average 6.1 7514.1 7.4 335.7
min 3.4 748.6 6.8 11.1
 max 12.4 44262.5 8.2 865.1

Environment - air emission

Sampling Result Standard

No Institution Parameter Keterangan
date Indoor Outdoor Indoor Outdoor
2x per year measurements.
Dinas Tata Ruang & Permukiman
Results are reported to the local
1 11-Feb-13 Balai Pengujian Mutu Konstruksi & Air emission (NOx) 16.07 14.5 5600 400
environmental government
Lingkungan
institution

2x per year measurements.

Dinas Tata Ruang & Permukiman
Results are reported to the local
2 11-Feb-13 Balai Pengujian Mutu Konstruksi & Air emission (SO2) 24.37 0.01 5200 900
environmental government
Lingkungan
institution
5.4 Kaizen Activities
6.1 Personel Records

EMPLOYEE TURNOVER
LEVEL Permanent Contract Total Turnover (pax) Turnover Rate (%)
Manager & Above 6 0 6 0 0.00%
Supervisor 22 0 22 0 0.00%
Staff 35 6 40 0 0.00%
Operative 172 103 262 0 0.00%
TOTAL 235 109 344 0 0.00%
% Total Turnover 0.00%
Turnover YTD FY 10 (Jan'13 - Dec'13) 0.08%
Budget Turnover FY11 4,0%

Accomplishment : turn over this month was ≤ 4%

Current Issues : How to maintain turnover rate below 5%.

Options: Ask employees resigned to fill exit interviews

Recommendation :

Action Plan : Immediately recruit substitution employees.

Formula for Monthly Employee Turnover Rate (%) = (# of employees who left company / Total employees this month) x 100

OVERTIME PERIODE JUNI 2013

Per-Departemant
OVERTIME HOURS
NO NAME of DEPARTEMANT TOTAL HEADCOUNT
TOTAL CALCULATION
1 ACCOUNTING 12 247.5 475.0
2 MAINTENANCE & ENG 28 1,775.0 3,637.5
3 PERSONALIA & GA 9 140.0 264.0
4 PRODUKSI 164 10,976.5 21,556.0
5 PURCHASING/PPIC 7 68.0 120.5
6 QUALITY CONTROL 37 2,196.5 4,735.5
7 WAREHOUSE - FD 15 309.0 586.3
8 WAREHOUSE - FG/RM 66 2,722.5 5,700.0
9 WAREHOUSE - SP 5 227.0 469.5
10 PLANT 1 - -
GRAND TOTAL 344 18,662.00 37,544.29

HEADCOUNT NUMBER (Full Time Equivalent)

Plant : Purwakarta
Month: June 2013
EMPLOYEE
No Position Overtime
DEPARTEMENT Head Count FTE
(hours/month)
1 Manufacturing Division PLANT - 0.00
2 Factory Manager PLANT 1 - 1.00
3 Purchasing/PPIC Manager PURCHASING/PPIC 1 - 1.00
4 Production Manager PRODUKSI 0 - 0.00
5 Project & Maintenance Manager MAINTENANCE & ENGINEERING 1 - 1.00
6 Quality Control Manager QUALITY CONTROL 1 - 1.00
7 Personnel & GA Manager PERSONNEL & GA 1 - 1.00
8 Finance & Accounting Manager ACCOUNTING 1 - 1.00
9 ACCOUNTING STAFF ACCOUNTING 7 192.50 8.11
10 ACCOUNTING SUPERVISOR ACCOUNTING 1 - 1.00
11 CASHIER WAREHOUSE - FG/RM 1 18.00 1.10
12 EDP SUPERVISOR WAREHOUSE - FD 1 - 1.00
13 TAX STAFF PURCHASING/PPIC 1 37.00 1.21
14 BOILER OPERATOR PRODUKSI 3 254.50 4.47
15 CIVIL & UTILITY MAINT. SPV. WAREHOUSE - FD 1 - 1.00
16 COMPRESSOR OPERATOR PRODUKSI 2 166.00 2.96
17 ELECTRICIAN WAREHOUSE - FG/RM 4 553.00 7.19
18 ELECTRICIAN UTILITIES WAREHOUSE - FG/RM 1 59.50 1.34
19 FORKLIFT TECHNICIAN PERSONALIA & GA 2 82.00 2.47
20 MAINTENANCE FOREMAN WAREHOUSE - FG/RM 2 111.00 2.64
21 Maintenance Planner & MW Offi WAREHOUSE - FG/RM 1 20.00 1.12
22 MAINTENANCE SUPERVISOR MAINTENANCE & ENGINEERING 1 - 1.00
23 MAINTENANCE TECHNICIAN ACCOUNTING 1 65.50 1.38
24 MECHANICAL WAREHOUSE - FG/RM 2 157.00 2.91
25 MEKANIK FORKLIFT WAREHOUSE - FG/RM 1 32.50 1.19
26 OPERATOR WWTP WAREHOUSE - FG/RM 2 105.50 2.61
27 SPV PROJECT & TECHNIC I PERSONALIA & GA 1 - 1.00
28 WATER TREATMENT OPERAT WAREHOUSE - FG/RM 1 40.50 1.23
29 WORKSHOP TECHNICIAN WAREHOUSE - SP 2 128.00 2.74
30 ADMINISTRATION & WAGES S WAREHOUSE - FG/RM 1 47.50 1.27
31 CHECKER SCRAP MAINTENANCE & ENGINEERING 1 23.50 1.14
32 GENERAL AFFAIR MAINTENANCE & ENGINEERING 1 52.00 1.30
33 GENERAL AFFAIR ASSISTANT PRODUKSI 1 - 1.00
34 INDUSTRIAL RELATION PRODUKSI 1 9.00 1.05
35 INDUSTRIAL RELATION & G.A PRODUKSI 1 - 1.00
36 OFFICE BOY PRODUKSI 1 8.00 1.05
37 ADMIN PROD & DAILY PROD PRODUKSI 1 55.50 1.32
38 ADMIN PRODUKSI PRODUKSI 1 57.00 1.33
39 CSD-FILLER OPERATOR PRODUKSI 6 620.00 9.58
40 CSD-INSPECTOR/RELIEF PRODUKSI 1 76.50 1.44
41 CSD-PACKER OPERATOR PRODUKSI 2 163.00 2.94
42 CSD-PET RINSER OPERATOR PRODUKSI 5 438.50 7.53
43 CSD-PET WARMER OPERATO WAREHOUSE - FD 3 289.00 4.67
44 CSD-PROD. FOREMAN ACCOUNTING 2 149.50 2.86
45 CUP LINE HELPER MAINTENANCE & ENGINEERING 14 464.50 16.68
46 CUP-ASST.FILLER OPERATO MAINTENANCE & ENGINEERING 1 104.00 1.60
47 CUP-FILLER OPERATOR WAREHOUSE - FD 17 1,864.50 27.76
48 CUP-PROD FOREMAN WAREHOUSE - FD 2 202.00 3.17
49 HELPER CSD WAREHOUSE - FD 30 1,331.00 37.68
50 HELPER PACKAGING WAREHOUSE - FG/RM 11 377.00 13.18
51 OPERATOR PRODUKSI MAINTENANCE & ENGINEERING 28 2,328.00 41.43
52 POSTMIX & BIB OPR PERSONALIA & GA 8 371.50 10.14
53 PREP-PROD. FOREMAN PERSONALIA & GA 3 219.00 4.26
54 PROD. CAPPER & INSPECTO PRODUKSI 3 227.00 4.31
55 PROD.CAN-DEPALITIZER OPR PRODUKSI 1 99.00 1.57
56 PRODUCTION CUP-AUTO PAC WAREHOUSE - FG/RM 6 487.50 8.81
57 PRODUCTION LINE FOREMAN PERSONALIA & GA 2 235.00 3.36
58 PRODUCTION POSTMIX & BI PERSONALIA & GA 1 87.00 1.50
59 PRODUCTION SHIFT SPV MAINTENANCE & ENGINEERING 3 - 3.00
60 PRODUCTION SUPERVISOR MAINTENANCE & ENGINEERING 2 - 2.00
61 SYRUP ROOM OPERATOR MAINTENANCE & ENGINEERING 4 272.50 5.57
62 TEA PREPARATION OPR MAINTENANCE & ENGINEERING 3 222.50 4.28
63 WATER TREATMENT OPERAT WAREHOUSE - FD 3 235.50 4.36
64 ADMIN PPIC MAINTENANCE & ENGINEERING 1 10.00 1.06
65 PPIC STAFF MAINTENANCE & ENGINEERING 1 2.50 1.01
66 PPIC SUPERVISOR PERSONALIA & GA 1 - 1.00
67 PURCHASING STAFF WAREHOUSE - FG/RM 3 55.50 3.32
68 QC ANALYST PRODUKSI 1 - 1.00
69 QC FIELD MAINTENANCE & ENGINEERING 17 1,326.00 24.65
70 QC FIELD COORDINATOR PRODUKSI 3 - 3.00
71 QC FINISHED GOOD PURCHASING/PPIC 2 236.50 3.36
72 QC FORMULATOR PURCHASING/PPIC 8 634.00 11.66
73 QC PROCESS SUPERVISOR PRODUKSI 3 - 3.00
74 QC SCIENTIFIC REGULATORY PRODUKSI 1 - 1.00
75 SENSORY ANALYST QUALITY CONTROL 2 - 1.00
 76 ADMIN FLEET & DELIVERRY PRODUKSI 1 70.50 1.41
77 ADMIN PROD & DAILY PROD PRODUKSI 1 49.00 1.28
78 DRIVER PRODUKSI 9 57.50 9.33
79 FLEET & DISTRIBUTION SPV PRODUKSI 1 - 1.00
80 FLEET DISPATCHER PRODUKSI 1 69.50 1.40
81 FOREMAN DISPACTHER PURCHASING/PPIC 1 34.00 1.20
82 MECHANIC QUALITY CONTROL 1 28.50 1.16
83 ADMIN FG QUALITY CONTROL 2 49.00 2.28
84 ADMIN RM QUALITY CONTROL 3 29.00 3.17
85 ADMIN WH-FG QUALITY CONTROL 1 65.50 1.38
86 ASSISTEN CHECKER FG QUALITY CONTROL 2 114.00 2.66
87 ASSISTEN CHECKER RM QUALITY CONTROL 4 183.50 5.06
88 CHECKER BM QUALITY CONTROL 3 122.00 3.70
89 CHECKER FG QUALITY CONTROL 5 254.00 6.47
90 CHECKER RM WAREHOUSE - SP 5 242.00 6.40
91 CHECKER SCRAP MAINTENANCE & ENGINEERING 1 44.00 1.25
92 CHECKER WH-FG WAREHOUSE - FG/RM 6 122.00 6.70
93 FOREMAN WH-FG WAREHOUSE - FG/RM 1 64.00 1.37
94 HELPER WAREHOUSE RM PRODUKSI 7 291.50 8.68
95 OPERATOR FORKLIFT ACCOUNTING 22 1,026.00 27.92
96 STOCK KEEPER FG PRODUKSI 1 - 1.00
97 STOCK KEEPER RM WAREHOUSE - FG/RM 2 116.00 2.67
98 WAREHOUSE SUPERVISOR MAINTENANCE & ENGINEERING 1 - 1.00
99 CHECKER SPARE PART PRODUKSI 4 227.00 5.31
100 SPARE PARTS SPV MAINTENANCE & ENGINEERING 1 - 1.00
6.2 Training Record

Training Record

BULAN

No TRAINING DEPARTMENT Jan'13 Apr'13 Total

PARTICIPANT COST PARTICIPANT COST COST

All Dept Head

1 Understanding HACCP QC & QA 7,500,000
& Supervisor
7,500,000

All Dept Head

2 Training 5 S HRD 9,000,000
& Supervisor
9,000,000

3 Trainign GA HRD
1 Staf GA 1,950,000 1,950,000

4 Training Basic HRD HRD

1 Spv 2,500,000 2,500,000

9
-
TOTAL - - 4,450,000 20,950,000
6.3 FACTORY VISIT RECORD

Month Jun-13
Number of
No Subject Date Department Remarks
Participants

All Department Head PCIB

1 Factory visit from PCIB & IASB June 18,2013 11
& Management IASB
6.4 CSR Program

Month Jun-13
Number of
No Subject Date Department COST
Participants
1 Blood Donor PMI ( Red Cross) Purwakarta 10 June 2013 85 All Department 2,639,250
Remarks