PROJECT – ADCS

(a project of automated data capturing system)

IPMI E-MBA Class Of March 2015

Innovation and Technology Commercialization

Group 2 – Queen Ratih:

Denny Situmorang, Irdam Tirto, Arief Sugito, Prasetyo Sumantri, Ratih Arie Utami
 BACK GROUND
PROJECT – ADCS
1. The differences of ERP (enterprise resources planning) cost accounting
modules versus numbers of actual RM (row materials) and FG (finished
goods) happened monthly in SFM (PT Sriboga Flour Mill); which is a
difference between the accounting data (were produced by ERP) and the
actual number proven monthly by inventory taking
2. To align between the financial report and actual condition was required
an adjustment figure called allowance amount which is around IDR 7
Billions a month
3. The unsynchronized numbers could be responsible by production
processing or/and collecting data performed manually by human being
4. Hence to ensure correctness of data, it is necessary to replace the
existing of a data human entering system by an automated data
capturing system provided directly by the machines (all weighing
devices)

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 BACK GROUND
PT SRIBOGA FLOUR MILL

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 BACK GROUND
PT SRIBOGA FLOUR MILL

• Founded by SRR (PT Sriboga Ratu Raya) located at Seaport of Semarang,

Central of Java – Indonesia
• Started operation by May 1999
• Process grain wheat become WHEAT FLOUR at 2,010 TPD (ton per day) &
flour extraction of 78% average – consists of 4 lines:
1. A Mill – 750 TPD
2. B Mill – 750 TPD
3. C Mill – 260 TPD
4. D Mill – 250 TPD
• Perform based wheat flour to be INOVA FLOUR at 10 TPD and PREMIX
FLOUR at 50 TPD
• Branding of > 100 of WHEAT FLOUR, > 25 of INOVA FLOUR and > 25 of
PREMIX FLOUR
• 2015 purchased/incoming wheat was +/- 500,000 MT vs 15,000,000 Bags
@25KG of WHEAT FLOUR + INOVA FLOUR + PREMIX FLOUR
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 PURPOSE
1. The project is intended to fulfil an ITC (innovation & technology commercialization)
program of eMBA (executive MBA) syllabus of IPMI (international business school) –
Jakarta, Indonesia.
2. Project – ADCS (the project of automated data capturing system) is targeted to collect data
straight away from the onsite processing spots and send them to a reporting system of ERP,
so that collecting data will be no longer interfaced by human errors
3. Result of ADCS must be able to guarantee the accuracy of data between ERP and the actual
condition
4. At the end a correct captured data will create a correct cost accounting management report
which is very important undertaken as a tool to control the whole operational
performances and ensure the correctness of the business process onsite
5. Hence, the allowance amount was given to make an adjustment for deviation between ERP
and actual condition (whose value approximately +/- 7 billion per month) shall be done in
emergency situation only by the authorized position/PIC and no longer can be done by the
“agreement” between the department of Accounting and Production during the execution
of stock opname
6. Furthermore any allowance that occur must be accountable and sought the cause for the
improvement of whole business processes in particular operational level

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 EXISTING DATA CAPTURING
Constrain:
1. Inaccurate data-weight caused by a high Error
due to the existing human data entering
system
2. Too complicated; Creates a data mixed up
between important & unimportant
3. High deviation reporting – ALWAYS needed a
manual adjustment / touchup
4. Existing system:
• Weigth – IN : Data entered by human
• Weight – PROCESS : Data entered by
human
• Numbers of bag – OUT : Data entered by
human
5. At ‘out’ stage, there is no system to provide
DATA – WEIGHT (data captured by Tally Man)
6. ‘Weight – out’ data provided by converting
from a bag numbers to a weight data system

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 GOALS
OBJECTIVE:

1. Whole activities; Data-weight at every stage (IN, PROCESS,

OUT) no longer captured by human and will be done by
ADCS
2. WEIGHT-IN: Weight of incoming wheat (in each storage silo)
will be based on ADCS of ‘WI’ Scale
3. WEIGHT-PROCESS:
• Weight of total wheat coming to Mills (A, B, C,D) will
be based on ADCS of “B1” Scales automatically
• Weight of FG (finished goods by means of wheat
flour, and by-products) produced by Mills will be
based on ADCS of “F1”, “F2”, “Bran” and “Pollard”
scales
4. WEIGHT-OUT: Weight of FG received by FG inventory (from
Mills, Inofa Plant and Premix Lines and By-products) will be
based on ADCS of additional scales (floor type)
5. Based Flour received by Inofa Plant will captured by ADCS of
“INOVA” scales
6. Base flour received by Premix Lines will captured by
“PREMIX” scales
7. Additives and Igredients received by Premix Lines will
performed by “PREMIX” scales
8. No deviation amount on result, so that no adjustment
needed on reporting

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 EXISTING WEIGHT MEASURING DEVICES (99 UNITS)

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 TARGET/SIMPLIFIED
TARGET DEVICES (62DEVICES
OF ADCS = 47 WEIGHING UNITS)

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 TARGET DEVICES (2 UNITS)

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 OBJECTIVE
WHEAT INTAKE & TRANSFER SCALES

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 OBJECTIVE
B1 SCALES MILL A/B/C/D

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 OBJECTIVE
F1 SCALES MILL A/B/C/D

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 OBJECTIVE
F2 SCALES MILL A/B/D

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 OBJECTIVE
BRAN SCALES MILL A/B/D

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 OBJECTIVE
POLLARD SCALES MILL A/B/D

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 OBJECTIVE
MIXERS/INOFA/PREMIXES SCALES

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 OBJECTIVE
25KG/1KG/JUMBO/FPS-IN/FPS-OUT SCALES

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 OBJECTIVE
BP PACKING MILL A/B/D

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 OBJECTIVE
GATE OFFICE SCALES

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 SEQUENCE
1. Capture data from equipment to onsite server database by ADCS vendor
– Modify existing hard-wares & system
– Capture 53 numerical data from equipment to database

2. Transfer data from onsite server to IT server database by IT Department

– Create 53 Data Coding from onsite server then transfer to IT Database Server
– Transfer 53 Data Numerical from onsite database IT Database Server

3. Review and modify ERP Modules by vendor to meet the requirement of

Cost Accounting Department; which is Accounting Management Reports
– Transfer 53 Data Coding from IT Database to ERP Server
– Transfer 53 Data Numerical from IT Database to ERP Server
– Modify all modules associated to cost accounting management reports

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 BUDGET
• Total of IDR 2,2 Bio capital expenses, consists of:

1. IDR 0.85 Bio for data capturing from weighing scales to

onsite database

2. IDR 0.35 Bio for data transferring from onsite to IT

Department database server

3. IDR 1,00 Bio for data transferring from IT Department

server to ERP + modify modules of cost accounting
management
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 TIME FRAME
• Total of 12 months of calendar to execute as follows:
1. 6 months by ADCS vendor
 2 months of materials indent
 1.5 months of modifying & upgrading equipment & system
 1.5 months of process numerical data capturing
 1 month of trial & finalizing
2. 2 months by IT Department
 1 months of character/coding data development
 1 month of data transferring to IT Server & trial
3. 4 months by ERP vendor
 1 month of materials indents
 1 month of data transferring to ERP server
 1 month of modification data & modules of cost accounting management
 1 month of integration & trial

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 ADCS HARDWARES
WEIGHING DEVICE TO PLC

CURRENT LOOP CONVERTER

SERIAL COMMUNICATION MODULE MITSUBISHI

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 ADCS HARDWARES
PLC TO DCS SOFTWARES

NETWORK MODULE
MITSUBISHI (MILL)
NETWORK MODULE NETWORK MODULE
SIEMENS (BUHLER MACHINE) MITSUBISHI (INOFA)

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 ADCS HARDWARES
DCS SOFTWARES TO ROW DATABASE SERVER
PLC SYSTEM FOR SCALES DATA LOGGER

DISPLAY
CPU
COMM MODULE

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 FOCUS ON REVIEW SOP
FPS-FLOUR
• No incoming product to FPS-Flour without weighing
1. BAG 25KG REGULAR FLOUR TO FPS-FLOUR
2. BAG 1KG REGULAR FLOUR TO FPS-FLOUR
3. BAG JUMBO REGULAR FLOUR TO FPS-FLOUR
4. BAG INOFA FLOUR TO FPS-FLOUR
5. BAG PREMIX FLOUR TO FPS-FLOUR
6. OTHER PRODUCTS TO FPS-FLOUR
• No outgoing product from FPS-Flour without weighing
7. BAG 25KG REGULAR FLOUR FROM FPS-FLOUR
8. BAG 1KG REGULAR FLOUR FROM FPS-FLOUR
9. BAG JUMBO REGULAR FLOUR FROM FPS-FLOUR
10. BAG INOFA FLOUR FROM FPS-FLOUR
11. BAG PREMIX FLOUR FROM FPS-FLOUR
12. OTHER PRODUCTS FROM FPS-FLOUR
• Delivery of direct loading bag flour
13. ONE TYPE ONE TRUCK: WEIGHING AT GO SCALE AFTER TRUCK FULL
14. MORE ONE TYPE ONE TRUCK: WEIGHING EVERY FULL TYPE AT GO SCALE
• Manage FPS-Flour as 2 (two) profit center by different floor coloring
15. PROFIT CENTER 1 FOR REGULAR & INOFA FLOURS
16. PROFIT CENTER 2 FOR PREMIX FLOURS

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 FOCUS ON REVIEW SOP
FPS-BP
• All incoming products to FPS-BP will be
captured by BP PACKING SCALES
17. BAG BRAN TO FPS-BP
18. BAG POLLARD TO FPS-BP
• All outgoing products from FPS-BP will be
captured by GO SCALES
20. BAG BRAN FROM FPS-BP
21. BAG POLLARD FROM FPS-BP
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 RECOMENDATION
1. FPS-Flour
 New layout for 1 GATE IN & 1 GATE OUT (± IDR 500 Millions)
 Or modify Business Process radically by means All Object
Weights coming from Flour Bins (Milling Flour Bins / Mixing
Flour Bins) are 100% Received & Responsible by FPS
(including weight deviation plus product sorting process for
quality & quantity)

2. Additional Scales (2 Units) to cover 12 Milling Flour Bins:

 For Data Weight Inside Each Bin (now only can be done in 18
Mixing Bins)
 For Flour Recipe/Mix inside Each Bag (now only can be done
in 18 Mixing Bins)
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 END
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