MONITORING DEFECT REJECT

AR Packaging Indonesia – Bekasi Plant

10th – 16th January 2020
(WEEK 2)
 PRINTING
(10th – 16th January 2020)
50000
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
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 TOP 3 WEEKLY DEFECT PRINTING
(10th – 16th January 2020)
35000

30000

25000

20000

15000

10000

5000

0 3
 Printing – Sorting Finished Goods

SPEED MASTER CDL 102

1.10 - Color Variation
(warna tidak sesuai 1.08 - Ink Skinning 1.02 - Scumming (Blobor)
DATE PRODUCTS NAME PPIC NO. UP No.
CR/WBS)
Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet)
MONDAY, FOLDING BOX PLAVIX 2X14 -1 A1912/B-0087 12 450 38 500 42
13/01/2020 DUS PDMBR085 A1912/B-0147 8 450 56 4650 581 1550 194
DOOS MELOXICAM 15 MG TABLET/50 A1912/B-0026 18 800 44 3300 183 500 28
DOOS CPG 75 MG TAB / 3X10 A1912/B-0062 6 1750 292 2500 417
TUESDAY, DOOS ATORVASTATIN 20 MG TAB/30 A1912/B-0073 15 310 21 1450 97
14/01/2020 FOLDING BOX PLATOGRIX TH A1912/B-0091 12 1600 133 2000 167
DUS PDMBR085 A1912/B-0147 8 294 37
SLEEVE PROMAG D.A / 6X6 S2001/B-0001 36 1300 36 1200 33
WEDNESDAY, DUS PDMBR085 A1912/B-0147 8 150 19
15/01/2020 DOOS PLANTACID SUSP / 100 ML K2001/B-0006 15 750 50
THURSDAY,
Neurobion Forte 10'S Folding Box PHL A1911/B-0165 4 50 13 50 13
16/01/2020
TOTAL 5110 360 13194 1277 7300 855

4
Printing - Sorting Finished Goods

SPEED MASTER CDL 102

1.10 - Color Variation
(warna tidak sesuai 1.08 - Ink Skinning 1.02 - Scumming (Blobor)
DATE PRODUCTS NAME PPIC NO. UP No.
CR/WBS)
Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet)
DUS PDMBR084 A1912/B-0029 8 1000 125 100 13
FRIDAY,
SLEEVE PROMAG D.A / 6X6 K1912/B-0005 36 1450 40 1000 28
10/01/2020
DOOS PROMAG D.A / 6X6 REV LOGO S2001/B-0002 16 8500 531 500 31
FUNGIDERM CREAM 5 MYANMAR DOOS
A1912/B-0070 55 2500 45 1000 18
SATURDAY, KARTONING (MJA)
11/01/2020 FUNGIDERM CREAM 10 DOOS KARTONING (MJA) A1912/B-0072 36 3000 83 2000 56 300 8
SLEEVE PROMAG D.A / 6X6 K1912/B-0005 36 250 7 1300 36
DUS PDMBR084 A1912/B-0029 8 250 31
MONDAY, FUNGIDERM CREAM 5 DOOS KARTONING (MJA) A1912/B-0071 55 2050 37 300 5 200 4
13/01/2020 FUNGIDERM CREAM 10 DOOS KARTONING (MJA) A1912/B-0072 36 3000 83 575 16 3000 83
DOOS PROMAG D.A / 6X6 REV LOGO S2001/B-0002 16 150 9
DUS PDMBR084 A1912/B-0029 8 375 47
TUESDAY, FUNGIDERM CREAM 5 DOOS KARTONING (MJA) A1912/B-0071 55 1000 18 300 5
14/01/2020 FUNGIDERM CREAM 10 DOOS KARTONING (MJA) A1912/B-0072 36 4000 111 1200 33
DOOS WOODS ES / 60 ML A2001/B-0003 15 50 3
DUS PDMBR084 A1912/B-0029 8 300 38 200 25 400 50
WEDNESDAY, PARAMEX NYERI OTOT-4 SHOW BOX (MJA) A1912/B-0066 4 300 75 400 100
15/01/2020 DUS PDMBR084 A1912/B-0148 8 450 56
DOOS WOODS ES / 60 ML A2001/B-0003 15 380 25
THURSDAY,
DUS PDMBR084 A1912/B-0148 8 900 113
16/01/2020
TOTAL 25755 1190 7775 299 9150 502 5
 Top 3 Defect Weekly - CDL 102 (PCS)
35000

30000

25000
Quantity (pcs)

20000

15000

10000

5000

0
Color Variation Scumming Ink Skinning Set Off 6
 Top 3 Defect Weekly - CDL 102 (SHEET)
2500

2000
Quantity (sheet)

1500

1000

500

0
Color Variation Scumming Ink Skinning Set Off 7
 Printing - Sorting Before Gluing

SPEED MASTER XL 105

1.10 - Color Variation
1.02 - Scumming (Blobor) (warna tidak sesuai 1.15 - Bald (Botak)
DATE PRODUCTS NAME PPIC NO. UP No.
CR/WBS)
Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet)
FRIDAY,
KAFT MIXAGRIP FLU & BATUK A1912/B-0095 12 1300 108 500 42 4650 388
10/01/2020
SATURDAY,
KAFT MIXAGRIP FLU & BATUK A1912/B-0095 12 1500 125 2000 167 6345 529
11/01/2020
MONDAY,
KAFT MIXAGRIP FLU & BATUK A1912/B-0095 12 6400 533 500 42
13/01/2020
TUESDAY,
CC. INZA (INZA KAPLET 4 CATCH COVER (MJA) A1911/B-0110 42 2500 60 1000 24
14/01/2020
CC. INZA (INZA KAPLET 4 CATCH COVER (MJA) A1911/B-0110 42 2000 48 3000 71
KAFT MIXAGRIP FLU & BATUK A1912/B-0095 12 1600 133 2500 208
WEDNESDAY,
DUS PDCKR094-R01 A1912/B-0118 6 650 108
15/01/2020
DUS BRE 800G KMI R18 A2001/B-0044 4 200 50
DOS MADURASA ORIGINAL 20 GR A2001/B-0081 9 50 6
CC. INZA (INZA KAPLET 4 CATCH COVER (MJA) A1911/B-0110 42 3000 71 2000 48
THURSDAY, DUS PDCKR097-R01 A1912/B-0120 4 30 8 30 8
16/01/2020 KAFT MIXAGRIP PSD EXP NIG A2001/B-0048 12 1050 88
DUS PDCKR096-R01 A2001/B-0072 4 850 213
TOTAL 20030 1457 12630 702 10995 916
8
 Printing - Sorting Finished Goods

SPEED MASTER XL 105

1.10 - Color Variation
1.02 - Scumming (Blobor) (warna tidak sesuai 1.15 - Bald (Botak)
DATE PRODUCTS NAME PPIC NO. UP No.
CR/WBS)
Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet)
FRIDAY,
SLEEVE PROMAG D.A / 6X6 K1912/B-0005 36 500 14
10/01/2020
WEDNESDAY, BOX NUFACORT CREAM A1912/B-0082 45 50 1
15/01/2020 DOOS PROCOLD FLU WITH PE KAPLET A1911/B-0057 5 75 15
TOTAL 0 0 625 30 0 0

9
 Top 3 Defect Weekly - XL 105 (PCS)
40000

35000

30000

25000
Quantity (pcs)

20000

15000

10000

5000

0
Color Variation Scumming Ink Skinning Bald Smudging 10
 Top 3 Defect Weekly - XL 105 (SHEET)
3500

3000

2500
Quantity (sheet)

2000

1500

1000

500

0
Color Variation Scumming Ink Skinning Bald Smudging 11
Printing – Sorting Finished Goods

SPEED MASTER 52
1.10 - Color Variation
(warna tidak sesuai - -
DATE PRODUCTS NAME PPIC NO. UP No.
CR/WBS)
Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet) Unit (pcs) Unit (Sheet)
THURSDAY,
DOOS MEROPENEM TRIHYDRATE 1 G INJ A1912/B-0109 2 1500 750
16/01/2020
TOTAL 1500 750 0 0 0 0

12
 Top 3 Defect Weekly - SM 52 (PCS)
8000

7000

6000

5000
Quantity (pcs)

4000

3000

2000

1000

0
Scumming Color Variation 13
 Top 3 Defect Weekly - SM 52 (SHEET)
6000

5000

4000
Quantity (sheet)

3000

2000

1000

0
Scumming Color Variation 14
 VARNISH & FOIL STAMPING
(10th – 16th January 2020)
300

250

200

150

100

50

0 15
Varnish & Foil Stamping – Sorting
Finished Goods
VARNISH & HOT STAMPING
MACHINE DATE PRODUCTS NAME PPIC NO. UP NO. DEFECT TYPE UNIT (pcs) Unit (Sheet)
SPEED MASTER WEDNESDAY,
DOOS PLANTACID SUSP / 100 ML K2001/B-0006 15 Coating not full 250 17
102 CDL 15/01/2020

16
 DIE CUTTING (CREASING)
(10th – 16th January 2020)

90000

80000

70000

60000

50000

40000

30000

20000

10000

0 17
 Cutting – Sorting Before Gluing

DIE CUTTING (CREASING)

MACHINE DATE PRODUCTS NAME PPIC NO. UP NO. DEFECT TYPE UNIT (pcs) Unit (Sheet)
TUESDAY,
GTP 2 SLEEVE PROMAG D.A / 6X6 S2001/B-0001 36 Print to cut misregistration 200 6
14/01/2020
TUESDAY,
DOOS ATORVASTATIN 20 MG TAB/30 A1912/B-0073 15 Print to cut misregistration 850 57
14/01/2020
IBERICA JR 105 DUS PDCKR096-R01 A2001/B-0072 4 Unregister emboss 550 138
THURSDAY,
BOX COLFIN SYR CARTONING DESAIN
16/01/2020 A2001/B-0057 15 Print to cut misregistration 200 13
BARU
TUESDAY,
DOOS MELOXICAM 15 MG TABLET/50 A1912/B-0026 18 Print to cut misregistration 68 4
14/01/2020
IBERICA JRK 105
WEDNESDAY,
DUS PDCKR094-R01 A1912/B-0118 6 Unregister emboss 280 47
15/01/2020
MONDAY, 8 Print to cut misregistration 2750 344
DUS PDMBR085 A1912/B-0147
13/01/2020 8 Unregister emboss 2000 250
TUESDAY, 8 Rough edges 600 75
BRAUSSE 2 DUS PDMBR085 A1912/B-0147
14/01/2020 8 Unregister emboss 900 113
WEDNESDAY, 8 Tear 100 13
DUS PDMBR085 A1912/B-0147
15/01/2020 8 Unregister emboss 5155 644

18
Cutting – Sorting Finished Goods

DIE CUTTING (CREASING)

MACHINE DATE PRODUCTS NAME PPIC NO. UP NO. DEFECT TYPE UNIT (pcs) Unit (Sheet)
FRIDAY,
SLEEVE PROMAG D.A / 6X6 K1912/B-0005 36 Print to cut misregistration 1450 40
10/01/2020
SATURDAY,
GTP 2 SLEEVE PROMAG D.A / 6X6 K1912/B-0005 36 Print to cut misregistration 200 6
11/01/2020
MONDAY,
SLEEVE PROMAG D.A / 6X6 K1912/B-0005 36 Print to cut misregistration 250 7
13/01/2020
MONDAY,
PRINT BOX CALLUSOL A1911/B-0089 24 Print to cut misregistration 6200 258
13/01/2020
IBERICA JR 105
TUESDAY,
PRINT BOX CALLUSOL A1911/B-0089 24 Print to cut misregistration 2250 94
14/01/2020
TUESDAY,
IBERICA JRK 105 DOOS WOODS ES / 60 ML A2001/B-0003 15 Print to cut misregistration 50 3
14/01/2020

19
 FOLDING & GLUING
(10th – 16th January 2020)
2500

2000

1500

1000

500

0 20
Folding & Gluing – Sorting Finished Goods

FOLDING & GLUING

MACHINE DATE PRODUCTS NAME PPIC NO. UP NO. DEFECT TYPE UNIT (pcs) Unit (Sheet)
WEDNESDAY,
GINSENG DOOS WOODS ES / 60 ML A2001/B-0003 15 Torn and Cracked 100 7
15/01/2020
SATURDAY,
FUNGIDERM CREAM 10 DOOS KARTONING (MJA) A1912/B-0072 36 Torn and Cracked 800 22
11/01/2020
MONDAY,
JINNYEU 650PC FUNGIDERM CREAM 10 DOOS KARTONING (MJA) A1912/B-0072 36 Torn and Cracked 500 14
13/01/2020
TUESDAY, KONICARE MINYAK TELON MALAYSIA 30 DOOS KECIL A1912/B-0068 20 Torn and Cracked 400 20
14/01/2020 FUNGIDERM CREAM 10 DOOS KARTONING (MJA) A1912/B-0072 36 Torn and Cracked 300 8
FRIDAY,
SLEEVE PROMAG D.A / 6X6 K1912/B-0005 36 Torn and Cracked 500 14
10/01/2020
WEDNESDAY,
JINNYEU BARU (2) BOX NUFACORT CREAM A1912/B-0082 45 Torn and Cracked 300 7
15/01/2020
WEDNESDAY,
FUNGIDERM CREAM 5 DOOS KARTONING (MJA) A1912/B-0071 55 Torn and Cracked 500 9
15/01/2020
TUESDAY,
NIKKO DUS PDMBR085 A1912/B-0147 8 Mis Gluing 110 14
14/01/2020
FRIDAY,
DOOS PROMAG D.A / 6X6 REV LOGO S2001/B-0002 16 Torn and Cracked 200 13
10/01/2020
SATURDAY,
PARAMEX NYERI OTOT-4 SHOW BOX (MJA) A1912/B-0066 4 Wrong folding 100 25
11/01/2020
MONDAY, PARAMEX NYERI OTOT-4 SHOW BOX (MJA) A1912/B-0066 4 Wrong folding 200 50
VESTA U/ DS. KCL
13/01/2020 DOOS PROCOLD FLU WITH PE KAPLET A1911/B-0057 5 Torn and Cracked 10 2
TUESDAY, 5 Excessive gluing 10 2
DOOS PROCOLD FLU WITH PE KAPLET A1911/B-0057
14/01/2020 5 Torn and Cracked 25 5
THURSDAY,
DOOS PROCOLD FLU WITH PE KAPLET A1911/B-0057 5 Torn and Cracked 10 2
16/01/2020 21
 SOFT LABEL
(10th – 16th January 2020)
8000

7000

6000

5000

4000

3000

2000

1000

0 22
Soft Label – Sorting Before Folding

SOFT LABEL
MACHINE DATE PRODUCTS NAME PPIC NO. UP NO. DEFECT TYPE UNIT (pcs) Unit (Sheet)
FRIDAY,
KAFT MIXAGRIP FLU & BATUK A1912/B-0095 12 Print to cut misregistration 265 22
10/01/2020
12 Print to cut misregistration 1600 133
SATURDAY,
KAFT MIXAGRIP FLU & BATUK A1912/B-0095 12 Wrong size 2000 167
11/01/2020
12 Eccentric blanks 3000 250
POLAR 115 MONDAY, KAFT MIXAGRIP FLU & BATUK A1912/B-0095 12 Print to cut misregistration 3600 300
13/01/2020 PIL VERORAB-1 A2001/B-0039 4 Rough edges 100 25
WEDNESDAY, 12 Print to cut misregistration 1050 88
KAFT MIXAGRIP FLU & BATUK A1912/B-0095
15/01/2020 12 Wrong size 507 42
THURSDAY,
KAFT MIXAGRIP PSD EXP NIG A2001/B-0048 12 Print to cut misregistration 200 17
16/01/2020

23
END TO END WASTE
COMPLAINT & REJECT
AR Packaging Indonesia – Bekasi Plant
2017 – 19th January 2020
 % End to End Waste
(2017 – January 2020) %End to End Waste
20.00% 2017 : 12.38%
2018 : 14.16%
18.00%
2019 : 12.37%
16.00% 2020 : 14.76%

14.00%

12.00% %Target 2020 :

Jan – Mar : 9%
10.00%
Apr – Jun : 8%
8.00% Jul – Dec : 6%
6.00%

4.00%

2.00%

0.00%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

25
 Quantity of External Reject (in PCS)
(2017 – 12th January 2020)
500,000,000 3.50%

450,000,000
2.98%
3.00%

400,000,000

2.50%
350,000,000

2.14%
2.08%
300,000,000
2.00%

250,000,000

1.50%
200,000,000

150,000,000
0.86% 0.86% 1.00%

100,000,000

0.50%
50,000,000

26
- 0.00%
2017 2018 2019 2020 Jan
 External Reject Cost (IDR)
(2017 – 12th January 2020)
Rp160,000,000,000.00 4.50%

3.96%
4.00%
Rp140,000,000,000.00

3.50%
Rp120,000,000,000.00

3.00%
Rp100,000,000,000.00
2.50%
2.50%

Rp80,000,000,000.00
2.04%
2.00%

Rp60,000,000,000.00
1.50%

Rp40,000,000,000.00 1.00% 1.00%

1.00%

Rp20,000,000,000.00
0.50%

27
Rp- 0.00%
2017 2018 2019 2020 Jan
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