TK23 - Final Report

UNIVERSITAS INDONESIA
SELF-HEALING CERAMICS FLOOR
FINAL REPORT
GROUP 23
GROUP PERSONNEL:
AFINII NURYATI (1606871455)

ALYA HAFIZA VIVADINAR (1606871493)
MERLANDO DANY SAPUTRO (1706104426)
NADIA SALSABILA (1606907934)
WULAN SILVIA RAMADHANI (1606907884)
ZATA AMALIA SIREGAR (1706104451)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
MAY 2019
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LIST OF GROUP MEMBER
1. Name : Afinii Nuryati

NPM : 1606871455
DOB : Jakarta, March 30th 1999
Address : PLN Raya street No.2a, Cinere
2. Name : Alya Hafiza Vivadinar

NPM : 1605871493
DOB : Tangerang, 29 April 1998
Address : Jl. Mega Kencana, F1 no. 9, Tangerang Selatan
3. Name : Merlando Dany Saputro

NPM : 1706104426
DOB : Ponorogo, August 12th 1995
Address : Taman Tridaya Indah E6 No.4, Tambun Selatan
4. Name : Nadia Salsabila

NPM : 1606907934
DOB : Tangerang, May 10th 1998
Address : Jl. Kh. Kilin, Batu Jaya, Batu Ceper, Tangerang.
5. Name : Wulan Silvia Ramadhani

NPM : 1606907884
DOB : Kuningan, January 10th 1998
Address : Dusun Karya Bhineka No. 13, Cirea, Mandirancan,
Kuningan
6. Name : Zata Amalia Siregar

NPM : 1706104451
DOB : Medan, April 11th 1996
Address : Jl. Young Panah Hijau, Medan
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FOREWORD
First of all, we would like thanks to God for his blessings and for giving us
the courage and strength to finish writing the final report of our Chemical Product
Design assignment. This final report presents our product design, which is a Self-
Healing Ceramics Floor - GrandNight. The second purpose of this report is to share
our research on this new product development, the manufacturing process, as well
as future prospects of pet products. Throughout the process of writing and
conducting the product development, we encountered many great challenges and
valuable lessons, and so, we would like to thank:
1. Dr. rer. Nat. Ir. Yuswan Muharam, M.T., for his supervision and guidance.
We are very grateful to have you as our supervisor,
2. Prof. Dr. Ir. Widodo W. Purwanto, DEA., Prof. Dr. Ing. Ir. Misri Gozan
M.Tech, and Ir. Dewi Tristantini, M.T., PhD. for all of your feedbacks and
input,
3. Our families who have supported us financially and morally, and of course
for putting up with us through thick and thin,
4. Our friends from Chemical Engineering Department batch 2016, especially
for our Chemical Engineering friends for the great and tough times we spent
together,
5. And other people who have helped and supported us along the way.
Lastly, we hope that this report may bring benefits and contribute to the
development of food, science, and technology. We realize that this report may lack
a few things, therefore we are very open to criticism and suggestions.
Depok, 17th May 2019

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ABSTRACT
SELF-HEALING CERAMICS FLOOR

Afinii Nuryati, Alya Hafiza Vivadinar, Merlando Dany Saputro, Nadia Salsabila,
Wulan Silvia Ramadhani, Zata Amalia Siregar
Chemical Engineering Department, Faculty of Engineering, Universitas
Indonesia, Depok, West Java, Indonesia.
Ceramics floor is a product that most building owners have. Ordinary ceramics floor
is known to break easily or brittle and easily scratched. Therefore, it is necessary to
develop ceramics floor to improve their performance. One of the things that can be
done is the use of smart material, so the material has a tendency to heal. Self-healing
ability in ceramics floor comes to solve the problem by making it from granite and
applying polyurethane coating to its surface. The main processes of manufacture
this product is making polyurethane coating and processing the granite to make it
into self-healing ceramics floor. The plant is located in Cilegon, providing
distribution to Sumatera and Java. The product will be sold at the price of IDR
350,000 for 60x60 cm size and IDR 480,000 for 100x100 cm size to the retailers
with IRR of 27,67%.
Keywords: self-healing, ceramics, polyurethane, coating, anti-scratch.

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EXECUTIVE SUMMARY
Ceramics floor is one of the most widely used materials in construction. The
demand for environmentally responsible construction and the ever more restrictive
environmental requirements derived from the legislation are increased in the
functional tiles. During the past decades, research in self-healing materials has
focused on the improvement in the mechanical properties, making stronger
materials, able to bear increasing solicitations.
Interviews and surveys are conducted to gather the needs, with contractors,
interior designers, architects, and high class people as target people. There are 27
needs interpreted from interviews. What customer needs the most is anti-scratch
ceramics floor. The collected needs are converted into specifications by first
arranging list of metrics. Then benchmarking with five existing products and setting
marginal and ideal value are conducted to get good predictive specification value.
The next thing to be concerned is the product concept. Concept generation
is proceeded by observing existing concepts and brainstorming new concepts. With
the big amount of concept, first selection using RVF is conducted to eliminate
redundant, vague, and foolish concepts, obtaining 33 from 60 concepts.
Two selection processes are conducted with the first, concept screening, as
comparative selection, produces 6 remaining concepts. The second selection is
scoring, based on detailed criteria of ease of use, self-healing scratch, self-healing
crack, manufacture process, ingredient availabililty, safety, durability, aesthetic,
toughness, and price. The six concepts are rated. The concept that has the highest
rank is “homogeneous structure ceramic with firing process for healing scratch by
polyurethane heat treatment” without combining it with other concept due to its
applicability and prices. Concept testing is proceeded in the form of direct
interviews showing that 84% of respondents will purchase the product, which
indirectly validating the concept.
The initial specifications are modified into final specification. The granite
product will have the ability to heal scratch with mechanism from cross-linking
bond in polyurethane coating. The homogeneous structure makes it stronger and
not easily cracked. The application of epoxy resin under the polyurethane layer also
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makes the floor more flawless. The ingredients needed to make this self-healing
ceramics floor are granite rocks, epoxy resin, dimethylbenzene, butyl acetate,
cyclohexanone, 1,4-butanediol (BDO), dibutylin dilaurate (DBTDL), toluene
diisocynate, polyether polyol HSH220, polyether polyol HSH330, and cardboard
box for packaging. The product will be available in the market with size 60x60 cm2
and 100x100 cm2 and approximately weight 7 kg/pcs for size 60x60 cm2.
The product is named “Grand Night” which represent the elegance of the
product and the glossy look of Grand Night floor pattern, and expected to be able
to work well and effectively with self-healing ability to solve the main problem of
ceramics floor like microcracks, scratch, etc. The tagline of this product is
“Technologies Right Under Your Feet”. “Technologies” means that the product is
applied with an innovation that makes the product performance better. The product
is expected to be in market by 2021. Production capacity is obtained from market
share which brings the production capacity to 832 m2 granite per day.
The ceramics floor production process in carried out in batch mode of
operation with processes broken down from granite blocks to granite slabs,
polishing, cut the granite slab according to the desired size, applying resin, applying
polyuethane, and packaging. On the daily basis, the overall ingredients input is 76.9
kg which gives overall product output 73 kg. Energy consumed per day is 66.65
kWh per day. They give the productivity measure of 0.95 kg product/kg ingredient
and energy utilization of 24 kWh/pcs.
The plant will be located in Cilegon industrial area which is near Merak Port
so the delivery of raw materials and production can be done easily and the cost can
be cheaper, and the plant will be operated 24 hours with 3 shifts of workers.
Active ingredients are many imported from China with the consideration of
cheaper price and availability in high purity. Daily production capacity of 1600
pieces (832 m2) need 92.4 cbm granite of raw materials, which are supplied and
inventoried in a fixed scheduling order. The order capacity is ordered with a surplus
of 120% on the first order as awareness to safety inventory. Grand Night will be
distributed to 7 cities with high number of building projects in Indonesia and
divided into 5 areas by own truck and freight forwarding service.
TABEL OF CONTENT
LIST OF GROUP MEMBER .............................................................................. ii

FOREWORD ........................................................................................................ iii
ABSTRACT .......................................................................................................... iv
EXECUTIVE SUMMARY ................................................................................... v
TABEL OF CONTENT ...................................................................................... vii
TABEL OF FIGURES .......................................................................................... x
LIST OF TABLES .............................................................................................. xii
LIST OF APPENDICES ................................................................................... xiv
CHAPTER 1 NEEDS AND IDENTIFICATION ............................................... 1
1.1 Background of Ideas .............................................................................. 1
1.2 Problem Identification ........................................................................... 1
1.3 Literature Reviews ................................................................................. 2
1.3.1. Definition and Function of Ceramic ................................................. 2
1.3.2. Granite ............................................................................................... 2
1.3.3. Making Process of Ceramics Floor ................................................... 3
1.3.4. Basic Principle of Self-Healing ......................................................... 5
1.3.5. Today’s Trends.................................................................................. 5
1.4 List of Needs ............................................................................................ 5
1.4.1 Determining Needs............................................................................ 5
1.4.2 Project Scope and Market Analysis .................................................. 6
1.4.3 Grouping the Needs........................................................................... 6
1.4.4 Needs Ranking .................................................................................. 7
1.4.5 Metric and Needs Grouping .............................................................. 8
1.5 Benchmarking ....................................................................................... 10
1.5.1 Bench Marking of Existing Product ................................................ 10
2.1 Concept Generation (Existing, New, Combined) .............................. 14
2.1.1 Existing Concepts ........................................................................... 14
2.1.2 New Concept ................................................................................... 15
2.1.3 Concept Generation ......................................................................... 15
2.2 Concept Selection ................................................................................. 16
2.2.1 Concept Screening .......................................................................... 17
2.2.2 Concept Scoring .............................................................................. 20
2.2.3 Concept Testing .............................................................................. 27
2.3 Final Specifications of Product ........................................................... 27
2.3.1 Product Specification ...................................................................... 27
2.3.2 Product Description ......................................................................... 28
2.3.3 Product Positioning ......................................................................... 29
CHAPTER III PROTOTYPE ............................................................................ 32
3.1. Brand ...................................................................................................... 32
3.2. Slogan ..................................................................................................... 32
3.3. Logo ........................................................................................................ 32
3.4. Product Prototype Design ....................................................................... 33
3.5. Packaging Prototype Design .................................................................. 33
CHAPTER IV ...................................................................................................... 35
PRODUCT MANUFACTURING ..................................................................... 35
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4.1. Market Analysis .................................................................................... 35
4.1.1 Market Opportunity ................................................................................ 35
4.1.2 Approximation Production Capacity using Demand-Driven Approach 37
4.2. Main Process Production ..................................................................... 38
4.2.1 Specific Description ............................................................................... 40
4.2.1.1Polyurethane Making Process ................................................................ 40
4.2.1.2Ceramics Floor Making Process ............................................................. 40
4.3. Main Process Equipment ..................................................................... 41
4.3.1 Granite Stone Lifting Machine ............................................................... 41
4.3.2 The Spreader Bar .................................................................................... 42
4.3.3 Gangsaw Machine .................................................................................. 43
4.3.4 Lift Arms Granite Cutting Machine ....................................................... 44
4.3.5 Automatic Polishing Machine for Granite ............................................. 45
4.3.6 Superline for Epoxy Resin ..................................................................... 45
4.3.7 Digital Bench Weighing Scale ............................................................... 46
4.3.8 Stirred Tank Reactor CSTR ................................................................... 47
4.4. Mass and Energy Balance Determining Performance ...................... 48
4.4.1 Mass Balance .......................................................................................... 48
4.4.2 Energy Balance ....................................................................................... 50
4.5. Performance Matrics............................................................................ 51
4.5.1 Throughput time ..................................................................................... 51
4.5.2 Process velocity ...................................................................................... 52
4.5.3 Productivity ............................................................................................ 52
4.5.4 Energy Utilization .................................................................................. 52
4.6. Plant Scheduling ................................................................................... 52
4.6.1 Primary Cutting ...................................................................................... 53
4.6.2 Polishing ................................................................................................. 53
4.6.3 Secondary Cutting .................................................................................. 53
4.6.4 Applying Epoxy Resin ........................................................................... 53
4.6.5 Weighting (Polyurethane production process) ....................................... 53
4.6.6 Polyurethane Primary Mixing (Polyurethane production process) ........ 53
4.6.7 Polyurethane Secondary Mixing (Polyurethane production process) .... 54
4.6.8 Polyurethane Final Mixing (Polyurethane production process) ............. 54
4.6.9 Applying Polyurethane ........................................................................... 54
4.6.10 Primary Packaging ................................................................................. 54
4.7. Plant Location and Layout .................................................................. 57
4.7.1 Plant Location ......................................................................................... 57
4.7.1.1Availability of Raw Materials ................................................................ 57
4.7.1.2Proximity to Market ............................................................................... 57
4.7.1.3Infrastructural Facilities ......................................................................... 57
4.7.1.4Government Policy ................................................................................. 57
4.7.1.5Availability of Human Resources .......................................................... 58
4.7.1.6Ecological and Environmental Factors ................................................... 58
4.7.2 Plant Layout ........................................................................................... 60
4.7.2.1Identification of Suitable Process Type .................................................. 60
4.7.2.2Selection of Suitable Layout Type ......................................................... 60
4.7.2.3Making a detailed layout ........................................................................ 61
CHAPTER 5 ........................................................................................................ 63
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5.1 Logistics of Raw Materials .................................................................. 63
5.1.1 Raw Material Supply....................................................................... 63
5.1.2 Raw Material Order Capacity ......................................................... 63
5.1.3 Raw Material Inventory .................................................................. 63
5.2 Product Distribution and Inventory ................................................... 64
5.2.1 Product Distribution Location and Pathway ................................... 64
5.2.2 Product Inventory ............................................................................ 66
5.2.3 Mode of Transportation................................................................... 68
5.3 Marketing Strategy .............................................................................. 69
CHAPTER 6 ........................................................................................................ 70
6.1 Total Capital Investment ..................................................................... 70
6.1.1. Fixed Capital ................................................................................... 71
6.1.2. Working Capital .............................................................................. 80
6.1.3. Total Capital Investment ................................................................. 81
6.2 Operational Cost................................................................................... 82
6.2.1. Direct Production Cost .................................................................... 82
6.2.2. Fixed Cost ....................................................................................... 85
6.2.3. Plant Overhead Cost ........................................................................ 86
6.2.4. General Expenses ............................................................................ 86
6.2.5. Summary of Operational Cost ......................................................... 89
6.3 Depreciation .......................................................................................... 92
6.4 Cost Breakdown ................................................................................... 92
6.5 Product Price ........................................................................................ 94
6.6 WACC and MARR .............................................................................. 94
6.7 Cash Flow .............................................................................................. 96
CHAPTER VII PROFITABILITY AND SENSITVITY ANALYSIS ........... 98
7.1. Rate of Return ...................................................................................... 98
7.2. Payback Period ..................................................................................... 98
7.3. Break Even Point ................................................................................ 100
7.4. Internal Rate of Return ..................................................................... 101
7.5. Net Present Value ............................................................................... 102
7.6. Sensitivity Analysis ............................................................................. 102
7.6.1. Selling Price Fluctuations ............................................................. 103
7.6.2. Raw Material Cost Changes .......................................................... 104
7.6.3. Operational Cost Changes ............................................................. 105
7.6.4. Loan Interest Changes ................................................................... 106
7.6.5. Fluctuation Graphics ..................................................................... 107
CONCLUSIONS ............................................................................................. 1100
Bidang Teknik Invensi .................................................................................... 1133
Latar Belakang Invensi ............................................................................... 1133
Ringkasan Invensi ....................................................................................... 1144
Uraian Singkat Gambar.............................................................................. 1155
Uraian Lengkap Invensi.............................................................................. 1166
Klaim ............................................................................................................ 1188
Abstrak ................................................................................................... 12020
REFERENCES ................................................................................................ 1266
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TABEL OF FIGURES
Figure 1. 1 Example of ceramics application for housing purposes ................. 2
Figure 2. 1 Existing concept of ceramics healing ............................................. 14

Figure 2. 2 New concept of ceramics healing .................................................... 15
Figure 2. 3 Generating concept of ceramics healing ........................................ 16
Figure 2. 4 Photos, Renderings, and Storyboard for The Product ................. 27
Figure 2. 5 Design of the ceramic ....................................................................... 29
Figure 2. 6 Conceptual map for product positioning ....................................... 30
Figure 3. 1 Logo of the products ........................................................................ 32

Figure 3. 2 Product prototype dimension ......................................................... 33
Figure 3. 3 Product prototype thickness ........................................................... 33
Figure 3. 4 Product Packaging Details .............................................................. 34
Figure 3. 5 Appearance of the product packaging ........................................... 34
Figure 3. 6 Front and back view of the product packaging ............................ 34
Figure 4. 1 GDP of Indonesia in 2000-2017 ...................................................... 35

Figure 4. 2 Supply and demand of Ceramics in Indonesia during 2009-2017
............................................................................................................................... 36
Figure 4. 3 Supply and demand during 2009-2017 with estimation during
2018-2020 ............................................................................................................. 36
Figure 4. 4 Block flow diagram of polyurethane making process ................. 39
Figure 4. 5 Block flow diagram of self-healing ceramics floor making process
............................................................................................................................... 39
Figure 4. 6 Granite Stone Lifting Machine ....................................................... 42
Figure 4. 7 The Spreader Bar M1 ...................................................................... 43
Figure 4. 8 Gangsaw Machine ............................................................................ 43
Figure 4. 9 Lift Arms Granite Cutting Machine .............................................. 44
Figure 4. 10 20 T Automatic Polishing Machine .............................................. 45
Figure 4. 11 Superline ......................................................................................... 46
Figure 4. 12 Digital Bench Weighing Scale ....................................................... 47
Figure 4. 13 Stirred Tank Reactor CSTR ......................................................... 48
Figure 4. 14 Plant Scheduling on Daily Basis (1st Batch)................................. 55
Figure 4. 15 Plant Scheduling on Daily Basis (2nd Batch)................................ 55
Figure 4. 16 Plant Scheduling on Daily Basis (3rd Batch) ................................ 56
Figure 4. 17 Location of Granite Floor Plant ................................................... 59
Figure 4. 18 Granite Plant Street View ............................................................. 60
Figure 4. 19 Plant Layout ................................................................................... 62
Figure 5. 1 Raw Material Inventory Chart per day......................................... 64
Figure 6. 1 Curve of Marshall & Swift Index Value ........................................ 72

Figure 6. 2 Cost Breakdown of Grand Night Ceramic Floor .......................... 93
Figure 6. 3 Cash Flow of 10 Years Lifetime Grand Night Product ................ 97
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Figure 7. 1 Cummulative Cash Flow vs. Year for Payback Period Calculation
............................................................................................................................. 100
Figure 7. 2 Net Present Value Fluctuation (60x60cm product size) ............. 107
Figure 7. 3 Net Present Value Fluctuation (100x100cm product size) ......... 107
Figure 7. 4 Internal Rate of Return Fluctuation (60x60cm product size) ... 108
Figure 7. 5 Internal Rate of Return Fluctuation (100x100cm product size) 108
Figure 7. 6 Payback Period Fluctuation (60x60cm product size) ................. 109
Figure 7. 7 Payback Period Fluctuation (100x100cm product size) ............. 109
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LIST OF TABLES
Table 1. 1 Grouping needs .................................................................................... 6

Table 1. 2 Grouping needs (Continued) .............................................................. 7
Table 1. 3 Needs ordered by rank ....................................................................... 7
Table 1. 4 Matrix of Needs and Metrics ............................................................. 9
Table 1. 5 Matrix of Needs and Metrics (Continued) ...................................... 10
Table 1. 6 List of Benchmarking........................................................................ 12
Table 2. 1 List of concept screening ................................................................... 18

Table 2. 2 Judgment score based on saaty's pairwase comparison index ...... 21
Table 2. 3 Description of Rating Score .............................................................. 24
Table 2. 4 Concept of scoring ............................................................................. 26
Table 2. 5 Final Spesifications ............................................................................ 28
Table 2. 6 Final Spesifications ............................................................................ 28
Table 4. 1 Commercial Demand Percentage from Indonesia Ceramics Tiles

Demand ................................................................................................................ 37
Table 4. 2 Production Capacity of the Product ................................................ 38
Table 4. 3 Forecasted Production Capacity ...................................................... 38
Table 4. 4 Granite Stone Lifting Machine ........................................................ 42
Table 4. 5 Specification Spreader Bar M1 ........................................................ 43
Table 4. 6 Specification of Gangsaw Machine .................................................. 44
Table 4. 7 Specification of Lift Arms Granite Cutting Machine .................... 44
Table 4. 8 Specification of 20 T Automatic Polishing Machine ...................... 45
Table 4. 9 Specification of Superline ................................................................. 46
Table 4. 10 Specification of Digital Bench Weighing Scale ............................. 47
Table 4. 11 Specification of Stirred Tank Reactor CSTR ............................... 48
Table 4. 12 Mass Balance Calculation Basis and Information ........................ 49
Table 4. 13 Mass Balance Calculation ............................................................... 49
Table 4. 14 Energy Consumption Calculation .................................................. 51
Table 4. 15 Plant Area Estimation ..................................................................... 61
Table 5. 1Product Distribution Location and Capacity .................................. 65

Table 5. 2 Product Distribution Pathway ......................................................... 66
Table 5. 3 Storage Inventory .............................................................................. 67
Table 5. 4 Specification and Price of the Truck ............................................... 69
Table 6. 1 Forecasting Marshall & Swift Index Value .................................... 72

Table 6. 2 FOB Price of All Equipment ............................................................ 73
Table 6. 3 Adjusted Cost of All Equipment ...................................................... 74
Table 6. 4 Land Cost Estimation ....................................................................... 75
Table 6. 5 Plant Area Cost Estimation .............................................................. 75
Table 6. 6 Supporting Facilities Cost Estimation ............................................. 76
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Table 6. 7 Utility Installation Cost Estimation ................................................. 78
Table 6. 8 Market Research Cost ...................................................................... 78
Table 6. 9 Patent, Industrial Design, and Brand Cost Estimation ................. 79
Table 6. 10 Indirect Cost and Total Fixed Cost Calculation ........................... 80
Table 6. 11 Working Capital Cost ..................................................................... 81
Table 6. 12 Total Capital Investment ................................................................ 81
Table 6. 13 Labor Salary .................................................................................... 82
Table 6. 14 Total Utility Cost ............................................................................. 83
Table 6. 15 Maintenance Cost ............................................................................ 84
Table 6. 16 Patent Registration Cost for Next Year 2nd-10th ........................ 84
Table 6. 17 Cost of Property Tax ....................................................................... 85
Table 6. 18 Tax Income Calculation .................................................................. 85
Table 6. 19 Insurance Calculation ..................................................................... 86
Table 6. 20 Communication Cost....................................................................... 87
Table 6. 21 Marketing Cost ................................................................................ 87
Table 6. 22 Product Distribution Frequency .................................................... 87
Table 6. 23 Product Distribution Cost .............................................................. 88
Table 6. 24 Source Proportion of Capital Investment ..................................... 88
Table 6. 25 Calculation of Loan Interest from Bank and Investor ................ 89
Table 6. 26 Summary of Operational Cost ....................................................... 90
Table 6. 27 Total Depreciation Calculation ...................................................... 92
Table 6. 28 Calculation of Cost Breakdown ..................................................... 93
Table 6. 29 Product Price Calculation for size 60x60 ...................................... 94
Table 6. 30 Product Price Calculation for size 100x100 .................................. 94
Table 6. 31 Calculation of WACC ..................................................................... 95
Table 7. 1 Payback Period Calculation ............................................................. 99

Table 7. 2 Breakeven Point Calculation based on Payback Period .............. 101
Table 7. 3 Selling Price Fluctuations for 60x60 cm Ceramics Floor ............ 103
Table 7. 4 Selling Price Fluctuations for 100x100 cm Ceramics Floor ........ 104
Table 7. 5 Raw Material Cost Fluctuations ................................................... 105
Table 7. 6 Operating Cost Fluctuation ............................................................ 106
Table 7. 7 Loan interest fluctuation ................................................................ 106
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LIST OF APPENDICES
Appendices A. Raw Material Suppliers .......................................................... 127

Appendices B. Raw Material Order Quantity ................................................ 129
Appendices C. Raw Material Cost .................................................................. 130
Appendices D. Utility Cost Breakdown........................................................... 131
Appendices E. Loan Interest ............................................................................ 134
Appendices F. Product Cash Flow ................................................................... 135
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CHAPTER 1
NEEDS AND IDENTIFICATION
1.1 Background of Ideas

Material development drives innovation. Better materials mean more data
storage, faster engines, stronger structures, and development of composite
materials. Structures can be built taller, with longer life time thanks to better
structural materials. A steady development of new materials and the improvement
of existing ones is a driving force of modern civilization. The ceramic materials
have been widely established in daily life such as home applications, industrial
applications, environmental applications, architectural applications, and in more
advanced technological applications. The subject of considerable research to the
need to improve the resistance of ceramic tiles in use, for instance, on floors of large
commercial areas.
Researchers have recently begun to develop materials that can repair
themselves if damage occurs as well as wounds that occur on the skin that will heal
by itself. This material is often referred to as self-healing materials. In general, all
synthetic materials or materials that can repair their own damage without human
intervention during the repair process can be called as self-healing materials. Self-
healing materials can be in the form of ceramics, granites, wood, polymers, and
metals, as long as the material can cover the damage that occurs to him. Basically,
all the materials can use with experience a period of time and cannot be used again
for several reasons. One of these is damage such as a broken, scratched, or cracked
(or wound in the case of the human body) due to external forces. Therefore, material
researchers think of making materials that can repair damage by themselves as
happens to the human body.
1.2 Problem Identification

Identification problems found on ceramic floors are as follows:
a. Almost all floor tiles are still easy to crack
b. Difficult to clean which causes black stains on ceramics
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c. Almost all ceramics are still susceptible to bacteria so that places that require
high sterility are very difficult
d. Almost all ceramics on wet or damp floors are susceptible to mold or
mildew causing the tile floor to become slippery
e. Almost all floor tiles are susceptible to scratches when exposed to sharp
objects
f. Ceramics on existing floors are heavy, hard, and easily broken when
supporting excessive loads then the ceramic slowly cracks
1.3 Literature Reviews
1.3.1. Definition and Function of Ceramic
A ceramic is an inorganic non-metallic solid made up of either metal or non-
metal compounds that have been shaped and then hardened by heating to high
temperatures. In other words, ceramics are what will left with when will take away
metals and organic materials (including wood, plastics, rubber, and anything that
was once alive). Mostly in daily life, ceramics are used for building purpose; walls
and floors.
Figure 1. 1 Example of ceramics application for housing purposes

(Source: www.pinkndecor.com)
1.3.2. Granite
One type of ceramics floor is granite tiles. Granite is an intrusive igneous
rock which is widely distributed throughout Earth’s crust at a range of depths up to
31 mi (50 km). Granite’s characteristic grainy structure and strength is the result of
many individual crystalline structures which form tightly together as magma slowly
cools within large, deeply buried rock bodies known as plutons. True granite
contains 20-60% quartz as well as both plagioclase and alkali feldspars of which
the former may not exceed general balance. Other minerals such as hornblende and
biotite may also occur in granite, accounting for its variety of appearances.
Commercially, the term ‘granite’ includes a range of other types of non-granite
dimension stone including any feldspathic crystalline rocks or other igneous or
metamorphic rocks which possess qualities similar to granite’s grainy, interlocking
texture. Many variations of granite appear on the commercial market with white,
gray, pink, and red being the most common primary colors. Greens and browns are
also available as well as darker grays and black.
1.3.3. Making Process of Ceramics Floor

The raw materials used in making ceramic tiles are abundantly available in
nature, such as clay, feldspar, and silica. Ceramics clay is dominated by the
chemical component SiO2 and Al2O3. There are several steps in the making process
that can be divided into steps below.
• Batching
Different raw materials at specific ratio and proportion from stock yard are
mixed by weight in the mixing storage without the presence of water.
• Ball Milling
Mixed raw materials are transported to ball mill via conveyor and are added
with calculated and measured amount of water then blended, homogenized and
grinned by means of alumina balls (or ceramic pellets) for hours to form slurry.
• Aging
The slurry is then transferred and stored into large cylindrical storage tank called
slurry tank for 24 hours. Inside the slurry tank, continuous agitation (scientific
work for mixing) of the slurry involving constant rotational speed of mixing
paddle is observed. This is to make sure that the slurry is continually
homogenized during aging period.
• Spray Drying
The spray dryer is equipped with nozzles which sprays the slurry into hot air to
remove water and produce powder or dust. The moisture content is reduced to
about 6 percent. Resulting powder are stored inside a certain storage called silo
tank. The powder is cured for 12 to 24 hours prior to its utilization in production.
• Dry Pressing
The main manufacturing procedure of these ceramic tiles initially starts during
pressing. Preserved powder inside silo tanks are transported into a large press
via conveyor, powered either with electricity or hydraulics. The press pushes
the dust into a set size and shape with a force ranging from a few hundred
pounds a square inch to 100,000 pounds per square inch. That pressure is what
gives the finished project its tensile strength. The form of initial solid unfired
ceramic body called green tile.
• Pre-heating (Drying)
After the green tile is formed, it simultaneously undergoes preheating or drying
at 100-400 degrees Celsius for hours or minutes to remove the remaining
moisture. This process is very important for the green tile to be stable and not
experience thermal shock which will result to breakage during firing process
inside the kiln. This will also make sure that the resulting products are strong,
durable and are free of defects.
• Glazing
There are many ways of applying glaze, from spray to water fall. This glazing
process is aimed for decorative purpose also to cover up pores after firing and
contribute hardness and durability of the resulting product. To give the tile some
color, pigments are mixed in with other additives that can increase the quality
of the tile. However, after glazing the tile will still look fairly pale.
• Firing
For more efficient purpose, the production process of ceramic tile uses
continuous kiln which include tunnel kilns and roller-hearth kilns (RHK). The
RHK is a type of continuous firing kiln with ceramic rollers which transport
ceramic tiles at different firing temperature with uniform temperature
distribution. The maximum temperature is 2500°F and usually at its 3rd quarter’s
section. The heat inside the kiln is precisely monitored and controlled by
computer. The higher the temperature, the stronger the tile.
• Sorting and Packaging
After firing, the tiles are transported into quality assurance department using
forklift for manual inspections. Sorting and packaging of ceramic tiles then
followed. Once the tiles are packed, they are placed in a warehouse for shipping.
1.3.4. Basic Principle of Self-Healing
Self-healing is the ability of a material to restore mechanical properties,
which were earlier perturbed by a plastic deformation or failure involving cracks,
scratches, and voids. Usually, certain properties of any engineering material such
as metals, polymers, ceramics, cementitious, and elastomeric and fibre-reinforced
composite materials degrade over time due to environmental conditions or fatigue
or due to damage incurred during operation. This damage is often on a microscopic
scale, requiring periodic inspection and repair to avoid them growing and causing
failure.
1.3.5. Today’s Trends

The ceramic tiles industry in Indonesia is having a fantastic growth in the
last few years. According to study done by TechSciResearch (2017), Indonesia tiles
market stood at $2.3 billion in 2016 and is projected to grow and reach $4.3 billion
by 2026. This growth can also be compared with other countries. Indonesia is
positioned as the 7th top manufacturing country, contributing 2.8% of the world
production. However, it also takes 2% of the world imports, since it is also 5th top
consuming country (MECS, 2017). This industry is projected to continue being the
dominant market (Transparency Market Research, 2018). That is because its high
consumption. Flooring is such a fundamental part of construction, it almost
unimaginable not to build a house without flooring. Indonesia also has some major
producer, such as Arwana Citra Mulia, Platinum Ceramic Indonesia, Indopenta
Sakti Teguh, etc. Looking at the case stated above, the ceramic tiles industry is a
prospective market to start a business for.
Indonesia’s trend on segmentation leans toward floor tiles, covering more
than three-forth market sales in 2016 (Ken Research, 2017). The consumer
preference is based on its economic prices, where ceramic floor tiles are more
economical compared to other material such as marble, stones, etc.
1.4 List of Needs
1.4.1 Determining Needs
Determining needs can be researched through a series of interview,
questionnaire, and research from internet and literature. This is done to understand
the needs of the future customers, thus understanding the framework of thinking for
choosing and buying a product. However, to a deliver a good question to consumer
and get precise solution for consumer need to restrict the problem first. Hence, must
frame the project scope first to get some ideas what needs to be expected.
1.4.2 Project Scope and Market Analysis
A project scope is constructed at the beginning of the product design. The
project scope for self-healing ceramics floors are:
a. Product: ceramics floors with a self-healing material
b. Timing: available around 2019/2020
c. Market: building in generals, specifically public building and smart home
enthusiast
d. Constraint: People with priorities over more affordable non-lasting
alternatives
e. Stakeholder: building corporations and building owners
1.4.3 Grouping the Needs
The needs of respondent can be arranged into several categories based on
the answer from respondent. It’s classify into five groups: safety, retailing, product
performance, operability, and product perception. Regulation group is a group
which is going to be used as a reference to develop the concept of self-healing
product that qualified with the Standar Nasional Indonesia (SNI)-13006 2010 for
ceramics product. Retailing group will be used as a reference to what will except
from self-healing ceramics floor product in marketing wise. Product performance
and operability groups are needs that classified as a self-healing ceramics floor
product able in doing the duty as self-healing product.
Table 1. 1 Grouping needs

Needs Number Need(s) Rank
A. SAFETY
7. Non-slip ceramics floors 3
8. Ceramics floor which have anti-micro bacteria agent 4
B. RETAILING
1. Ceramics floor which have affordable price 3
11. Ceramics floor which have vary of size 3
Table 1. 2 Grouping needs (Continued)
Needs Number Need(s) Rank
12. Ceramics floor which are accessible to buy in many 4
places
C. PRODUCT PERFORMANCE
3 Anti-crack ceramics floor (Self-Healing ability) 5
4. Easy to clean ceramics floor 5
5. Ceramics floor which are easy to be maintained 4
9. Tough ceramics floor (anti-scratch) 4
10. Easy to dry ceramics floor 3
D. OPERABILITY
6. Lightweight ceramics floors 3
13. Ceramics floors which are flexible condition usage 5
requirement
E. PRODUCT PERCEPTION
2. Ceramics floor that have interesting variety of 4
appearance
1.4.4 Needs Ranking

Needs that score 5 indicate that they are essential criteria and required to be
in a product. Needs that fall into “highly desirable” that needs category are expected
by most customers to this product. Existing products possess a few of these needs,
but some are supposed to be improved. “Nice to have” means that needs are not
necessarily have to be in product, but if they were, it will add value
1: Undesirable, 2: Not important, 3: Nice to have, 4: Highly desirable, 5: Essential.
Table 1. 3 Needs ordered by rank

Need
Needs Rank
Number
ESSENTIAL
3. Anti-crack ceramics floor (Self-Healing ability) 5
4. Easy to clean ceramics floor 5
Table 1.2 Needs ordered by rank
Need Needs Rank
Number
13. Ceramics floors which are flexible condition usage 5
requirement
HIGHLY DESIRABLE
8. Ceramics floor which has anti-micro bacteria agent 4
5. Ceramics floor that are easy to maintained 4
9. Tough ceramics floor (anti-scratch) 4
2. Ceramics floor that has interesting variety of 4
appearance
12. Ceramics floor that are accessible to buy in many 4
places
NICE TO HAVE
7. Non-slip ceramics floors 3
1. Ceramics floor which have affordable price 3
10. Easy to dry ceramics floor 3
6. Lightweight ceramics floors 3
11. Ceramics floor that has vary of size 3
1.4.5 Metric and Needs Grouping

The next step is making a matrix of needs and metrics. This step will help
us to see if there are some needs which have same metric units. If there are some
needs that have same metric unit, that doesn’t mean have to erase one or some of it.
Because there’re some needs that has subjective specification, it’s possible to have
needs that have same metric.
Table 1. 4 Matrix of Needs and Metrics
Metrics
%WA (Water Absorption)

Need
psi/ MPa
Minutes
Unitless
Yes/No
Group
Subj
IDR
cm2
Description
kg
Coefficient
of friction ●
(COF)
Safety Presence of
anti-micro
●
bacteria
agent
Affordable
●
Price
Have small
to medium ●
Retailing
size
Accessible
to buy in ●
many places
Qualified
thermal or
●
toughness
test
Product
Self-
Performance
healing ●
agent
Cleaning
●
time
Table 1. 5 Matrix of Needs and Metrics (Continued)
Metrics
%WA (Water Absorption)

Need
psi/ MPa
Group
Minutes
Unitless
Yes/No
Subj
IDR
Description
cm2
kg
Protective
●
coating
Abrasion
●
resistance
Drying rate ●
Weight ●
Can be
Operability used
●
indoor and
outdoor
Product Variety of ●
Perception appearance
1.5 Benchmarking
1.5.1 Bench Marking of Existing Product
As conceptual product that will move forward to its production scale, the
product needs benchmarking. Benchmarking is a way to determine the superiority
of the products to be production of other products that similar and have been
producing in the market. The necessity to conduct benchmarking is vital, because
produce a product that must be able to compete with existing products in the market
overall. The result from benchmarking also help us to project the market segment
for the product, so variable require to scale up will be analyze, and or further
modification so it will meet both the market share and customer needs.
Table 1. 6 List of Benchmarking
Competitor
Need Oceanland
Need(s) Rank Specification(s) Unit Overland Ceramics Varmoraa Surestone Roman
Number (Product of
(Product of China) Ceramics (Granite) Ceramics
China)
SAFETY
Coefficient of Not
9. Non-slip 3 Unitless Not slippery ● ● Not slippery
Friction slippery
Humidity % Humidity ● ● ● ● ●
New improvement
12, 15, Presence of anti-
such as Anti-micro 4
16. micro bacteria Yes/No No Yes No Yes Yes
bacteria
agent
RETAILING
Rp Rp 160.000 – Rp 56.000 – Rp 87.000 –
1, 21, Rp 28.000- Rp
Affordable price 3 Price IDR 112.000/ Rp 560.000/ Rp 85.000 Rp 150.000
22, 23. 700.000 /m2
m2 m2 /m2 /m2
30x30 cm2, 30x60 30x30cm2
Have a small to 2 40x40cm2 to 20x20cm2 to
19. 3 Product Size Cm cm2, 60x60cm2, to 60x60cm2
medium size 100x100cm2 60x60cm2
60x90cm2 80x120cm2
Accessible to buy in Quantity in
20. 4 Yes/No No No No No Yes
many places Market
PRODUCT PERFORMANCE
Qualified
Anti-crack ceramics Thermal or Yes/No Yes Yes No No No
3, 7, 24,
floor (Self-Healing 5 Toughness Test
25.
ability) Self-healing Yes/
No No No No No
agent No
13
Table 1. 6 List of Benchmarking (Continued)

Competitor
Need Oceanland
Need(s) Rank Specification(s) Unit Overland Ceramics Varmoraa Surestone Roman
Number (Product of
(Product of China) Ceramics (Granite) Ceramics
China)
4,10. Easy to clean 5 Cleaning time Minutes ● ● ● ● >5
Protection Yes/
5, 6. Easy to maintain 4 Yes Yes Yes Yes Yes
Coating applied No
Tough ceramics floor Rupture
13, 14. 4 MPa >35 MPa > 40 MPa 15.5 Mpa >37.2 MPa >22 MPa
(anti-scratch) Modulus
Water % Water
17. Easy to dry 3 0.08% 0.06% 0.37% 0.08% < 0.1%
Absorption Absorption
OPERABILITY
Weight kg ● ● ● ● 0,624-5
8. Lightweight 3 9.5
Thickness Mm 9.5 mm 10 mm 9.5-11mm 10mm
±0.1mm
18, 26, Have flexible 5 Can be used
27. condition usage indoor and Yes/No Yes No Yes Yes Yes
requirement outdoor
PRODUCT PERSPECTIVE
2, 11. interesting appearance 4 Design Subjective Yes Yes Yes Yes Yes
requirement outdoor
PRODUCT PERSPECTIVE
2, 11. Have interesting 4
Design Subjective Yes Yes Yes Yes Yes
variety of appearance
requirement outdoor
PRODUCT PERSPECTIVE
2, 11. Have interesting 4
Design Subjective Yes Yes Yes Yes Yes
variety of appearance
Universitas Indonesia
14
CHAPTER II
CONCEPT AND FINAL SPESIFICATION
2.1 Concept Generation (Existing, New, Combined)

2.1.1 Existing Concepts
In mapping the existing concepts, the whole existing ceramics floor is divided
according to some criteria, which are the material, method, cause of damage, and how
to deal with damage. The existing concept of ceramics floor is illustrated as follow.
Figure 2. 1 Existing concept of ceramics healing
15
2.1.2 New Concept

Based on todays’ demand of ceramics floor product, a few new innovations on
product concept is really feasible to be made. The purpose of integrating new concept
is to get an even better product in quality that cannot be fulfilled by the existing ones.
The new concept is generated by brainstorming in a more lateral way of thinking. The
concept tree describing the new concept to decide which one to implemented is
provided as follow.
In terms of mechanism or work principle and ingredient to perform specific
function, a new innovation of ceramics floor products containing material for ceramics
structure that can be repairing ceramics crack or ceramics scratch as healing agent is
proposed as it is more efficient if can be applied well. These new innovations include
the principal of physical, chemical, and mechanical. The purpose of integrating several
principals is to get an even better performance of product rather than the existing
concept. There are a few methods that can be enhanced too with the utilization of
multifunction ingredients. The important terms on the new concept is described as
follow.
Figure 2. 2 New concept of ceramics healing
2.1.3 Concept Generation

After Authors get existing concept and new concept, Authors combine both
existing and new concept to be screened later.
16
Figure 2. 3 Generating concept of ceramics healing

2.2 Concept Selection
There are three steps to do a concept selection, which are concept screening,
scoring, and testing. Each step uses certain method which will be described below. This
concept selection process is done by evaluating concepts, comparing the relative
strengths and weaknesses of each concepts so then Authors can objectively select one
of the best concepts of solar charger device.
17
2.2.1 Concept Screening

2.2.1.1 Rate the Concept
There are 6 criteria that Authors choose based on the discussion and literature
review from assignment 1 (needs order by rank), the criteria are listed as follows:
1. Ease of use
Ease of use means how easy the finished product is to use by its intended users.
2. Performance
This criterion shows whereas the product can heal itself if damage occur.
3. Ease of manufacture
This criterion shows how complicated the process to manufacture the product, also
the availability of the ingredients or materials.
4. Safety
Safety means this product is not harmful to users and the environment. Dangers to
users can be fatal so that products that are not safe for users are highly discouraged.
5. Price affordability
6. High durability
Durability is product's ability to perform (self-healed) repeatedly so it can last long.
7. Good aesthetic
8. Toughness
Toughness shows how well the material can resist fracturing when force is applied.
After specified the criteria and done the matrix of ideas then Authors do the
ranking by giving score of one concept, compared to the reference concept.
• Score plus (+) to indicate that the concept has better quality than reference concept
• Score minus (-) to indicate that the concept has lower quality than the reference
• Score zero (0) to indicate that the concept has same quality as reference concept.
2.2.1.2 Rank the Concept
After each concepts are assessed, the number of “+”, “-“, and “0” are summed.
From that value, which concepts are eliminated and which concepts are pass to the next
selection stage will be obtained. From concept ranking, Authors choose concepts that
have value of 2 or above to be scored in concept scoring.
18
Table 2. 1 List of concept screening
Criteria H II III IV V VI X XII XIII XIV XV XVI XIX XX XXI XXII XXV XXVII XXVIII XXIX
Ease of Use 0 + - + - + + + + + + + - - - - + + + +
Performace 0 0 0 0 + + 0 0 + 0 + + 0 0 0 + 0 0 + +
Ease of
0 0 0 0 - - 0 0 0 0 - - 0 0 0 - 0 - - -
Manufacture
Safety 0 0 - - 0 0 0 0 0 0 0 0 0 - - 0 0 - 0 0
Price 0 0 0 0 - - 0 0 - - - - 0 0 0 - 0 0 - -
Durability 0 0 0 0 + + - 0 + 0 0 + 0 0 0 + 0 0 + +
Aesthetic 0 - - 0 - - - - 0 0 0 - - - - - - - 0 0
Toughness 0 + + + + + + + + + + + + + + + + + + +
Total 0 1 -1 1 0 0 0 1 3 1 1 1 -1 -2 -2 0 1 -1 2 2
Selections NO NO NO NO NO NO NO NO YES NO NO NO NO NO NO NO NO NO YES YES
Rank 4 3 6 3 4 4 4 3 1 3 3 3 6 7 7 4 3 6 2 2
19
Table 2.1 List of concept screening (continued)

Criteria H XXX XXXII XXXIII XXXIV XXXV XXXVI XL XLII XLIII XLIV XLV XLVII XLVIII XLIX L
Ease of Use 0 + + - + - - + + + + + + - + +
Performace 0 + 0 0 0 + + 0 0 + 0 + 0 0 0 +
Ease of
0 - 0 0 0 0 0 0 0 0 0 0 - - - -
Manufacture
Safety 0 0 0 - - - - - - 0 0 0 0 - - 0
Price 0 - 0 0 0 - - 0 0 - - - 0 0 0 -
Durability 0 + 0 0 0 + + 0 0 + 0 0 0 0 0 +
Aesthetic 0 0 - - 0 0 0 - - 0 0 0 - - 0 -
Toughness 0 + 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Total 0 2 0 -3 0 -1 -1 -1 -1 2 0 1 -1 -4 -1 0
Selection NO YES NO NO NO NO NO NO NO YES NO NO NO NO NO NO
Rank 4 2 4 8 4 6 6 6 6 2 4 3 6 9 6 4
20
Table 2.1 List of concept screening (continued)
Criteria H LI LV LVI LVII LVIII LIX LX

Ease of Use 0 + + + + + + +
Performace 0 + + 0 + + 0 +
Ease of
0
Manufacture - 0 0 0 - - -
Safety 0 0 0 0 0 0 0 0
Price 0 - - - - - - -
Durability 0 + + 0 0 + 0 0
Aesthetic 0 - 0 0 0 0 0 0
Toughness 0 0 0 0 0 0 0 0
Total 0 0 2 0 1 1 -1 0
Selection NO NO YES NO NO NO NO NO
Rank 4 4 2 4 3 3 5 4
2.2.2 Concept Scoring

2.2.2.1 Prepare the Selection Matrix
Before Authors prepare the weight factors for each of the criteria. Authors first
determined more criteria to specify and select the concept. These criteria are developed
from several criteria used in the screening with a more detailed definition. These
criteria are ease of use, self-healing scratch, self-healing crack, manufacture process,
ingredient availability, safety, durability, aesthetic, toughness, and price.
To prepare the weight factors, Authors use Saaty’s pairwise comparison scale
which are adapted from the Analytical Hierarchy Process (AHP). Using that
comparison scale, Authors compare each of the criterion to each other in the matter of
their importance, needs, and engineering value. This is to help us compare which of the
criteria Authors need to prioritize more. Below are the results of the criteria weight
factors. In the table below, below each of the criterion column are the original number
judgment in respect to each other. Below the priority column are the weight factors that
is going to be used later in rating the concept.
21
Table 2. 2 Judgment score based on saaty's pairwase comparison index
Judgment Score based on Saaty's Pairwase Comparison Index

Self- Self-
Criteria Ease of Manufacture Ingredient Priority
healing healing Safety Durability Aesthetic Toughness Price
use process availability
scratch crack
Ease of use 1 0.333 0.333 0.167 0.167 0.125 0.143 0.333 0.2 3 0.117
Self-healing
3 1 0.333 0.2 0.2 0.143 0.125 0.167 0.167 2 0.050
scratch
Self-healing
3 3 1 0.2 0.2 0.143 0.125 0.167 0.167 0.143 0.021
crack
Manufacture
6 5 5 1 0.167 0.143 0.143 0.167 0.167 0.5 0.036
process
Ingredient
6 5 5 6 1 0.125 6 8 6 2 0.135
availability
Safety 8 7 7 7 8 1 8 9 7 7 0.329
Durability 7 8 8 7 0.167 0.125 1 7 0.167 1 0.090
Aesthetic 3 6 6 6 0.125 0.111 0.143 1 0.333 2 0.080
Toughness 5 6 6 6 0.167 0.143 6 3 1 0.25 0.085
Price 0.333 0.5 7 2 0.5 0.143 1 0.5 4 1 0.058
22
Brief description of each criterion is discussed as follows.

● Ease of use (11.7%)
Ease of use is the criterion which describes the weather the concept needs a
specialty of skills, tools or treatment to use the product. Ceramics tiles are
mostly used as flooring because of their simplicity of usage. Based on the
interview, most of the respondents said that they chose ceramics as their
flooring tiles due to its ease of maintenance as well.
● Self-healing scratch (5%)
Since Authors would like to have a self-healing ceramics floor, Authors divided
their capability to healing scratches and crack. For scratches, Authors defined
this criterion as their ability to self-healing while there is a scratch.
● Self-healing crack (2.1%)
Authors also define this criterion as their ability to self-heal a crack. This also
includes their operating conditions, such as temperature and time of healing.
● Manufacture process (3.6%)
Authors define manufacturing process as the steps needed to produce the
product. This is because the more difficult the product to be made, the more
costly the manufacturing process. This in the end can affect the price of the
product, which Authors would like to reduce a little bit due to the respondents’
needs in the first survey.
● Ingredient Availability (13.5%)
Ingredient availability is also judge due to its effect to prices. Ingredient
availability means how difficult the ingredients of the product are to obtain and
how common it is in the market.
● Safety (32.9%)
This criterion is defined to see whether product is harmful to the environment
or not. This is the most important criterion since Authors almost can see and
use ceramic tiles in daily life. Hence, safety is the most concerning since
Authors don’t want to be harmed by the product, Authors used for almost 24
hours.
23
● Durability (9%)
Durability is defined whether the product can self-heal several times or once
and how long the self-heal ability can last for.
● Aesthetic (8%)
Aesthetic is one of the most important things the respondents’ factors to choose
ceramics floor as their flooring preferences. This is why Authors use aesthetic
as one of the criteria. Aesthetic is defined whether the self-healing capability
would ruin the aesthetic of the product or not.
● Toughness (8.5%)
Authors defined toughness in a range of toughness in MPa.
● Price (5.8%)
Lastly, prices are one of the most important things the respondents’ needs.
Authors define price in a range of number usually a ceramic would be sold.
2.2.2.2 Ranking the Concept

Authors rated to the concept to the criteria. However, Authors need parameters
to rate the concept. Authors decided to use five different parameters for each score that
are given below
24
Table 2. 3 Description of Rating Score
Price in
Rat Self-healing Self-healing Manufacturi Ingredient Toughn
Ease of Use Safety Durability Aesthetic Rupiahs/
ing scratch crack ng Process Availability ess
packaging
Requiring very Requiring
Very difficult Ruining the
difficult to very Containing all
Cannot self- Cannot self- to obtain and aesthetic until it <15.5
1 obtain complex harmful Cannot self-heal >500k
heal heal not common looks very MPa
additional tools manufacture chemicals
in use unappealing
or treatment steps
Ruining the
Tools are Requiring 5- Difficult to Self-healing can only
Very Very Containing 3- aesthetic until it 15.5
difficult to 7 major obtain and not happen once and the
2 high/low high/low 5 harmful looks MPa-20 401k-500k
obtain and not manufacturin common in self-healing lifetime
temperature temperature chemicals moderately MPa
common g steps use ability is defined
acceptable
Requiring
Achievable Achievable Containing 2- Self-healing can only 2-3 types of
additional tools Requiring 3- Easy to obtain
high/low high/low 3 harmful happen multiple minor changes 21
that are easy to 4 major but no
3 temperature, temperature, chemicals or times, but the self- of the aesthetic MPa-25 101k-400k
be found but manufacturin common in
but time but time has the ability healing lifetime (scratch line, MPa
need a long- g steps use
consuming consuming to crack ability is undefined spots)
time treatment
Achievable Achievable
Requiring Requiring <3 Self-healing can only
high/low high/low <2 types of
additional tools manufacturin happen multiple
temperature temperature Easy to obtain Containing <2 minor changes 26
that are easy to g steps with times, but the self-
4 or room or room and common harmful of the aesthetic MPa-33 50k-100k
be found, but difficult healing lifetime
temperature temperature in use chemicals (scratch line, MPa
short time operation ability is short (<2
and short and short spots)
treatment condition years)
time needed time needed
Requiring <3 Self-healing can only
Requiring no Room Room manufacturin Very easy to Not happen multiple
34 MPa
additional tools temperature temperature g steps with obtain and containing times, but the self- Not ruining the
5 – 100k-150k
and no to short and short and short simple common in harmful healing lifetime aesthetic at all
45MPa
time treatment time needed time needed operation use chemicals ability is long (>2
condition years)
25
2.2.2.3 Ranking the Concept

Rank of the concept is based on the scoring from the highest to the lowest score.
As stated in advance, the concept that has the highest score or the highest rank based
on the concept rating would become the best concept and would be chosen as the main
concept to be developed as a new product. To rank the product, Authors first rate the
product with their weighted and see which has the biggest score.
𝒏
𝑺𝒋 = ∑ 𝒓𝒊𝒋 𝑾𝒊 . . . (𝟏)
𝒊=𝟏
Where:
𝑺𝒋 = 𝒕𝒐𝒕𝒂𝒍 𝒔𝒄𝒐𝒓𝒆 𝒇𝒐𝒓 𝒄𝒐𝒏𝒄𝒆𝒑𝒕 𝒋
𝒓𝒊𝒋 = 𝒓𝒂𝒘 𝒓𝒂𝒕𝒊𝒏𝒈 𝒇𝒐𝒓 𝒄𝒐𝒏𝒄𝒆𝒑𝒕 𝒋 𝒇𝒐𝒓 𝒊𝒕𝒉 𝒄𝒓𝒊𝒕𝒆𝒓𝒊𝒐𝒏
𝑾𝒊 = 𝒘𝒆𝒊𝒈𝒉𝒕𝒊𝒏𝒈 𝒇𝒐𝒓 𝒊𝒕𝒉 𝒄𝒓𝒊𝒕𝒆𝒓𝒊𝒐𝒏

𝒏 = 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒄𝒓𝒊𝒕𝒆𝒓𝒊𝒐𝒏
26
Table 2. 4 Concept of scoring
XIII XXVIII XXIX XXX XLIII LV

Criteria Weight
Weighted Weighted Weighted Weighted Weighted Weighted
Rating Rating Rating Rating Rating Rating
Score Score Score Score Score Score
Ease of use 0.117 4 0.466006 2 0.233003 5 0.582507 3 0.349504 4 0.466006 4 0.466006

Self-healing
scratch 0.050 5 0.251381 5 0.251381 1 0.050276 4 0.201105 5 0.582507 5 0.582507
Self-healing
crack 0.021 3 0.062536 3 0.062536 1 0.020845 2 0.041691 3 0.349504 3 0.349504
Manufacture
process 0.036 5 0.182083 1 0.036417 1 0.036417 1 0.036417 5 0.582507 5 0.582507
Ingredient
availability 0.135 5 0.674709 3 0.404825 3 0.404825 4 0.539767 5 0.582507 5 0.582507
Safety 0.329 5 1.643016 5 1.643016 5 1.643016 5 1.643016 3 0.349504 3 0.349504
Durability 0.090 5 0.447841 5 0.447841 1 0.089568 2 0.179136 5 0.582507 5 0.582507
Aesthetic 0.080 5 0.401819 5 0.401819 5 0.401819 5 0.401819 5 0.582507 5 0.582507
Toughness 0.085 5 0.42299 5 0.42299 5 0.42299 5 0.42299 1 0.116501 1 0.116501
Price 0.058 2 0.115771 1 0.057885 2 0.115771 2 0.115771 3 0.349504 2 0.233003
Sum of score
1.00 4.67 3.96 3.77 3.93 4.54 4.43
Rank 1 4 6 5 2 3
27
The concept that has the highest rank is concept XIII. Concept XIII is
homogeneous structure ceramic with firing process for healing scratch by
polyurethane heat treatment. Based on group decision, Authors would accept
concept XIII without combining it with other concept due to its applicability and
prices. Therefore, concept XII is decided to be the product concept. This concept
would next be proceeded to product testing.
2.2.3 Concept Testing

Concept testing will prove the acceptability and potency of the product’s
concept if Authors continue the development and launch the product.
The concept is communicated in the following ways.
• Verbal description: Homogeneous Structure Self-Healing Ceramics Floor
with Polyurethane Coating described in short paragraph.
• Photos and renderings: Renderings –nearly photo realistic illustrations of
the concept will be given to communicate the product to the respondents.
• Storyboard: A series of images of how the product work with its special
performance. These methods are used because of some limitations and
consideration for the easiest method to be done. Besides, these methods still
give a good response if Authors give appropriate questions.
Figure 2. 4 Photos, Renderings, and Storyboard for The Product
2.3 Final Specifications of Product

2.3.1 Product Specification
After conducting concept elimination, screening, scoring and then testing
the chosen concept to customer, Authors finally have the specification of the
28
product that meet consumer needs. The chosen concepts will be joined with the
specification on this product. Authors eliminated some specifications and add some
new specifications to adjust customer’s need and help the manufacturing process of
the product. The final specifications are given in metric below.
Table 2. 5 Final Spesifications
Specification Unit Own Product

Rock Type Unitless Granite
Glazing %weight Epoxy Resin
Polyurethane Weight ratio Dimethylbenzene (24.9%w)
composition Butyl acetate (24.9%w)
Cyclohexanone (12.4%w)
1,4-Butanediol (BDO) (2.3%w)
Dibutyltin dilaurate (DBTDL) (2.3%w)
Toluene diisocyanate (9.9%w)
Polyether polyol HSH220 (20.9%w)
Polyether polyol HSH330 (2.3%w)
Table 2. 6 Final Spesifications
Specification Unit Own Product

Non-slip Unitless Not slippery
Affordable price Rupiah > 400,000
Product size cm2 60x60 and 100x100
Water absorption % Water 10%
Absorption
Toughness Mpa >12
Self-healing ability Unitless Polyurethane coating
Safety Registration Unitless
2.3.2 Product Description

Based on the survey, the most respondent expected that ceramics has self-
healing scratch ability with good toughness so it will have more lifetime. By looking
at the existing products, most of the ceramics tile are designed only for specific
29
functional so Authors made the new ceramics with additional features. The new
product principle of this concept is the ceramics with self-healing scratch ability by
polyurethane that have good durability and toughness to reduce cracking on the
surface of the ceramics.
This product containing self-healing ability that can healing scratch using
polyurethane. The healing can be adopted from cross linked bond polyurethane by
addition of compound containing hydrogen. This bond will have a tendency to keep
polymer structure stable. When the scratch appeared and cut off polymer bonds,
with stimulation of heat treatment, the chain mobility will be increased then tend to
reconnect each other and returned to normal. The temperature used to support self-
healing is between 40-120oC. It can be obtained by the help of heating equipment
like hair dryer. Moreover, this product will have a better toughness than ordinary
ceramics because the structure is already homogeneous. Homogeneous structure
attained from the material which is granite rocks which has better toughness than
ordinary ceramic mixture after passing the firing process. Furthermore, it uses
opaque glazing under the polyurethane coating that makes variety of ceramics style
so it looks more aesthetic and not slippery then more safety for indoor use,
especially in a room that has a high probability of shifting items, for example when
you are in public spaces and office, then it will minimize the occurrence of a scratch
that can lead to crack in ceramics.
Figure 2. 5 Design of the ceramic
2.3.3 Product Positioning

After determining product specifications and descriptions, it is important to
know the position of the new product compared to the existing products for the
purpose of market opportunity. To address this instance, a perceptual mapping is
30
generated to compare the new product with some existing products simultaneously,
which is illustrated as follow.
Conceptual Map for Product Positioning

Our Products Overland Ceramics
Varmoraa Ceramics Surestone (Granite)
Oceanland Roman Ceramics

Ease of use
5
Toughness 4 Performance
3
2
1
Aesthetic 0 Ease of manufacture
Durability Safety
Price
Figure 2. 6 Conceptual map for product positioning
There are five existing products to be compared with the developed concept
of the new product. Those five products are the same as the ones that have been
benchmarked before to aid to the formation of the initial product specification.
These products are Overland Ceramics, Varmoraa Ceramics, Surestone (Granite),
Oceanland, and Roman Ceramics.
The parameters used to compare these products are also used in the screening
and scoring process. The brief scoring explanation of each category for each
product is then described.
• Ease of use
This parameter addresses how easy the product can be used. This is to
help us compare the products to its competitors in the aspect of easiness from
the customer’s perspective. Ease of use is rated by their ability to be use for its
purposes based on the necessity of additional tools or treatment. New product
is given 4 while existing products are 5 since Authors need an additional
treatment to activate their specialty when other products do not.
• Performance
31
This parameter is evaluated by the performance of ceramics floor to self-

healing. The five existing products get the lowest score (1), because they do
not have self-healing ability. Meanwhile, new product gets the highest score
(5) because it is designed to have self-healing ability when the ceramics floor
is being scratched.
• Ease of manufacture
The ease of manufacture is mainly evaluated by the ability of raw
material and the manufacture process. The existing and new products get the
same score which are 5 because all products have the same easiness of
manufacturing process.
• Safety
All products have passed regulations showing that with the appropriate,
so all products get a fair five.
• Price
This parameter addresses the competitive process each of the products
have. Oceandland gets 5 because it has the cheapest price range, while
Overland gets 5 dues to its wide range of prices. Surestone, Roman Ceramics,
and new product get 4 since they have the similar range prices. Varmoraa
Ceramics has the lowest score since it is the most expensive.
• Durability
This parameter is evaluated the durability of ceramics to self-heal, such
as multiple or once. New product get five since it can self-heal multiple times.
Meanwhile, other existing products get 1 since they do not have self-healing
ability, but have a good toughness.
• Aesthetic
For this parameter, existing and new products get a fair five since they
all have a varied design for customers to choose.
• Toughness
This toughness parameter is based on the rupture modulus. Overland and
new product get the highest score since they have the highest rupture modulus,
while other existing products are ranked and scored from the next highest to
the lowest modulus.
32
CHAPTER III
PROTOTYPE
3.1. Brand
The name of our brand is “Grand Night”. This name means own ceramics
floor is impressive in size, appearance, and its effect. This “Grand Night” product
is expected to be able to work well and effectively with self-healing ability to solve
the main problem of ceramics floor like microcracks, scratch, etc. The background
of our brand because it is catchy since it is a derived from granite a type of stone to
make our ceramics.
3.2. Slogan
The tagline of this product is “Technologies Right Under Your Feet”.
“Technologies” means that the product is applied with an innovation that makes the
product performance better. The technology on the product is self-healing scratch
ability on ceramics floor with polyurethane coating. “Under Your Feet” mean this
product are more right under people’s feet which is the existence is very close with
human life.
3.3. Logo
Its color and shape are chosen for both its artistic value and meaningful
philosophies. The color, dark blue and terracotta, chosen because dark blue
represents a good calming atmosphere, something everybody wants for a
community building, one with a massive number of visitors, or for a home, and
terracotta represents a vibrant, exciting, yet still hides a mystery. The “GN” shape
inside the circle is the initial of the brand “Grand Night”, the circle and half of the
circle shape symbolize the moon, while the stars are symbolized by the two little
dots, representing the night in our brand. The slogan are written under the logo, to
market our slogan more to the market.
Figure 3. 1 Logo of the products

33
3.4. Product Prototype Design

The prototype of the product is a thin polished granite tiles with 600x600 mm2
and 1000x1000 mm2 size, and 12 mm thickness. The pattern of granite depends on
the location where raw materials are mined. Therefore, there will be many
variations of its pattern. The tile is covered with transparent epoxy resin and
transparent polyurethane layer so it has an ability to healed from scratch. The
scratch can be healed because the polyurethane contains a cross-linking bond.
When scratch appears, consumers just have to wait until the scratch heal for
approximately 24 hours in room temperature. It will save more cost because
consumers don’t need to replace the floor with new one.
Figure 3. 2 Product prototype dimension
Figure 3. 3 Product prototype thickness

3.5. Packaging Prototype Design
Tiles are packed in double-walled cardboard with the size that can be adjusted
depending on the size of the ceramic that will be in the package. For example,
ceramics packaging with size of 600mm x 600mm with box weight 28 kg and
height/thickness of tile is 12 mm, so that each of the first package can contains up
to 4 granites. The color of this package will be brown with Grand Night logo tagline
and some regulation-obligated content. The secondary packaging will be made of
34
double-walled cardboard too which is each of the secondary package can contains
up to 8 boxes of primary package. The color of this package will be brown with
Grand Night logo tagline. Tiles are further packed into sea worthy wooden crates
or wooden pallets. Polythene wrapper is made to cover the entire material inside
the wooden crate for extra safety from getting scratches during transit. The wooden
crate contains up to 4 boxes of secondary package. The wooden crate is strapped
and tightened by steel bands. Slabs are well packed in wooden crates with polished
face to face. The final product is packed in sea worthy wooden crates in order to
avoid any breakage or loss during transit. Product can be distributed using
containers after the secondary package already in wooden crates.
Figure 3. 4 Product Packaging Details
Figure 3. 5 Appearance of the product packaging
Figure 3. 6 Front and back view of the product packaging
35
CHAPTER IV
PRODUCT MANUFACTURING
4.1. Market Analysis

The goal of market analysis is to analyze the target markets. This is done by
projecting the demand when the plant is ready for production. Hence, the
production capacity planned will not be underspecified or over-specified.
4.1.1 Market Opportunity
Before determining the production capacity, it is important to see the
opportunity of selling the product. Thus, several methods of determining the
product is done. First, Gross Domestic Product (GDP) is analyzed and forecasted
throughout the product lifetime. Second, a supply and demand graphic is projected
to see how the product is going to do in the supply and demand balance.
GDP represents the economic growth of one country. Since the target market
is located in Indonesia, we analyze the GDP of Indonesia. For simplicity, GDP is
analyzed from 2000. Indonesia’s GDP is shown in the graphic below, which data
we got from World Bank.
GDP of Indonesia in 2000-2017

1.2
Trillions
1
0.8
0.6
0.4
0.2
0
1995 2000 2005 2010 2015 2020
Figure 4. 1 GDP of Indonesia in 2000-2017

(Source: World Bank Data, 2019)
According to the data, Indonesia’s GDP has an increasing trend. The growth
rate for 2017 is 5.068%. With this in mind, it can be concluded the product can be
received based on the economic circumstances. With a good growth, it can also be
concluded that the factory capacity for this product can be increased with less risk.
36
Supply-demand analysis is also done by gaining data of supply and demand

of ceramics tiles in Indonesia. Since the data is limited, after 2017, we forecasted
the data until 2020, which is the year the product is launched and the production
operation started, using the production growth percentage for supply and GDP
growth for demand, assuming the growth for the demand and economic growth is
the same. Thus, supply and demand before and after estimation can be seen below.
Supply and Demand of Ceramics in

Indonesia during 2009-2017
500
Millions
400
300
200
100
0
2008 2010 2012 2014 2016 2018
Supply Demand
Figure 4. 2 Supply and demand of Ceramics in Indonesia during 2009-2017

(Source: Ceramics World Review, 2018)
Supply and Demand during 2009-2017 with

Estimation during 2018-2020
600000000
500000000
400000000
300000000
200000000
100000000
0
2008 2010 2012 2014 2016 2018 2020 2022
Supply after estimation Demand after estimation
Figure 4. 3 Supply and demand during 2009-2017 with estimation during 2018-2020
It can be seen in the graphic that although the supply was lower than demand
in 2016, in 2017, it became higher as well. This trend stays if we forecast the supply
and demand to 2020. It is because the ceramics industry in Indonesia is also focused
37
to be exported. Therefore, we use demand-driven approach product capacity

approximation to determine the production capacity.
4.1.2 Approximation Production Capacity using Demand-Driven Approach
Approximation using demand-driven approach is calculated by using the
demand in the year production started and the market share wanted. Since ceramic
tiles are used in many kinds of building, it is simplified and grouped into four types
of application, such as residential replacement, commercial, new residential
application, and other application.
Since the target market is public spaces and mass building, the ceramic tiles
type we use is the commercial application. According to Transparency Market
Research (2017), the percentage of usage in 2017 according to global demand are
48.9% for residential replacement, 30.7% for commercial application, 22.29% for
new residential application, and 14.78% for other application. Since the percentage
needed is only limited to Indonesia area only, thus the percentage from global
demand is multiply to Indonesia to Global GDP ratio.
𝐼𝑛𝑑𝑜𝑛𝑒𝑠𝑖𝑎′ 𝑠 𝐺𝐷𝑃 𝑖𝑛 2017
𝐼𝑛𝑑𝑜𝑛𝑒𝑠𝑖𝑎 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑢𝑠𝑎𝑔𝑒 % 𝑖𝑛 2017 = × 𝑤𝑜𝑟𝑙𝑑 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑢𝑠𝑎𝑔𝑒 %
𝑊𝑜𝑟𝑙𝑑′ 𝑠 𝐺𝐷𝑃 𝑖𝑛 2017
1.02 𝑡𝑟𝑖𝑙𝑙𝑖𝑜𝑛
𝐼𝑛𝑑𝑜𝑛𝑒𝑠𝑖𝑎 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑢𝑠𝑎𝑔𝑒 % 𝑖𝑛 2017 = × 30.7% = 0.42%
75 𝑡𝑟𝑖𝑙𝑙𝑖𝑜𝑛
However, that percentage is Indonesia’s commercial usage from the global
demand. Since the data obtained before was Indonesia’s demand, the percentage is
converted to cover from Indonesia’s demand. The world demand is 13.3 billion m2
in 2017. Therefore, the calculation is done like below.
𝐼𝑛𝑑𝑜𝑛𝑒𝑠𝑖𝑎 𝑐𝑜𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑑𝑒𝑚𝑎𝑛𝑑 % 𝑖𝑛 2017
𝐺𝑙𝑜𝑏𝑎𝑙 𝐶𝑒𝑟𝑎𝑚𝑖𝑐 𝑑𝑒𝑚𝑎𝑛𝑑 𝑖𝑛 2017 × 𝐼𝑛𝑑𝑜𝑛𝑒𝑠𝑖𝑎 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑢𝑠𝑎𝑔𝑒% 𝑖𝑛 2017
=
𝐼𝑛𝑑𝑜𝑛𝑒𝑠𝑖𝑎 𝑐𝑒𝑟𝑎𝑚𝑖𝑐 𝑑𝑒𝑚𝑎𝑛𝑑 𝑖𝑛 2017
13.3 𝑏𝑖𝑙𝑙𝑖𝑜𝑛 𝑚2 × 0.42%
𝐼𝑛𝑑𝑜𝑛𝑒𝑠𝑖𝑎 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑑𝑒𝑚𝑎𝑛𝑑 % 𝑖𝑛 2017 = = 14.27%
387.45 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑚2
Assuming the growth demand is the same for growth in percentage, this
percentage can be forecasted to 2020.
Table 4. 1 Commercial Demand Percentage from Indonesia Ceramics Tiles Demand
Year 2017 2018 2019 2020
% commercial demand from
14.27% 14.99% 15.73% 16.52%
Indonesia demand
38
If assumption taken for market share is 0.3% and 300 working days, the
production capacity in year 2020 is shown below.
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑖𝑛 2020
= 𝑓𝑜𝑟𝑒𝑐𝑎𝑠𝑡𝑒𝑑 𝑑𝑒𝑚𝑎𝑛𝑑 𝑖𝑛 2020
× % 𝐼𝑛𝑑𝑜𝑛𝑒𝑠𝑖𝑎 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑑𝑒𝑚𝑎𝑛𝑑 𝑖𝑛 2020 × 𝑚𝑎𝑟𝑘𝑒𝑡 𝑠ℎ𝑎𝑟𝑒
= 387.45 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑚2 × 16.52% × 0.3%
𝑚2
= 222304 = 741 𝑚2 /𝑑𝑎𝑦
𝑦𝑒𝑎𝑟
There are two types of design we made for our ceramics, the 60 x 60 and 100 x 100.
The production capacity specifically for both types is shown below.
Table 4. 2 Production Capacity of the Product
Percentage Production Capacity
Type (cm) Area of
Pieces/year Pieces/day Package/Year Package/Day
Production
60 x 60 0.36 58% 358157 1194 89539 298
100 x 100 1 42% 93368 311 23342 78
Total Production Capacity in
451525 1505 112881 376
2020
Assuming the growth of production capacity is the same as demand growth, the
projected increase during the lifetime is shown below.
Table 4. 3 Forecasted Production Capacity
Year Production Capacity (m2)
2020 370507
2021 389033
2022 408484
2023 428909
2024 450354
2025 472872
2026 496515
4.2. Main Process Production
Self-healing ceramics floor are processed based on batch system. It means
that the raw materials are processed in series of operations in order to create one
whole end product. The main reasons of using batch system operation for this
39
ceramics floor are to maintain the quality of the ceramics floor by controlling the
operating factor.
The production process of the ceramics floor consists of 2 stages, which are
making polyurethane coating and processing the granite to make it into self-healing
ceramics floor. The making of polyurethane coating consist of 2 stages, which are
weighting and mixing the raw materials. The are 5 kinds of raw materials which are
used in this making process, those are Polyether polyol HSH220, HSH330, 1,4-
butanediol (BDO), Dibutyltin dilaurate (DBTL), Dimetyl benzene, Butyl acetate,
and Cyclohexanone. For processing the granite, it consists of 5 steps, which are
primary cutting, polishing, secondary cutting, applying epoxy resin, and applying
polyurethane. The following block diagram summarizes the entire process.
Figure 4. 4 Block flow diagram of polyurethane making process
Figure 4. 5 Block flow diagram of self-healing ceramics floor making process
40
4.2.1 Specific Description

Below are the specific and detailed description for Grand Night Ceramics
Floor manufacturing process.
4.2.1.1 Polyurethane Making Process
• Weighting polyurethane material
There are five types of materials which are needed to make TDI-polyurethane.
There are Polyether polyol HSH220, HSH330, 1,4-butanediol (BDO), Dibutyltin
dilaurate (DBTL), Dimetyl benzene, Butyl acetate, and Cyclohexanone. The first
step is weighting all of the raw materials according to the formula. The solvents
(Dimetyl benzene = 24.9%w, Butyl acetate = 24.9%w, and Cyclohexanone =
12.4%w), 1.4-Butanediol (BDO) (2.3%w), Dibutyltin dilaurate (DBTDL) (2.3%w),
Toluene diisocyanate (9.9%w), and Polyether polyol HSH220 (20.9%w) and
Polyether polyol HSH330 (2.3%w) from the formula.
• Mixing
A mixture of dewatered HSH220 and HSH330 were poured into mixing tank
to produce TDI. The TDI was then fed into CSTR reactor and reacted at 75 °C.
After that, BDO and DBTDL were added and fully mixed at 50 °C. Then the
mixture was allowed to react at 70°C. Solvent comprised of dimethylbenzene, butyl
acetate and cyclohexanone (w/w/w 2:2:1, dewatered) was added at the end of the
reaction. After passing all of the process, TDI-Polyurethane is ready to be applied
to the ceramics floor.
4.2.1.2 Ceramics Floor Making Process
The self-healing ceramics floor will have two types of sizes, which are 60x60
cm and 100x100 cm. So, it will also need two different sizes of granites as raw
materials. For 60x60 cm, the granite size is 3,0x1,8 m and for 100x100 cm is 3x2
m.
• Primary cutting
The first step of this manufacturing process is primary cutting. Primary
cutting is an operating unit which is useful for cutting the granites into slabs. For
60x60 cm ceramics, the 3x1,8 m granite will be cut into 200 slabs with 1,8x1,2 m
size and 1,5 cm thick. For 100x100 cm ceramics, the 3x2 m granite will be cut into
41
200 slabs with 2x1 m size and 1,5 cm thick. Then the slabs will be separated from
the stones by chipping.
• Polishing
After primary cutting, granite slabs will be delivered to polishing machine.
Polishing is done for making the granite slabs look more shiny by removing the
scratches, unwanted lines, and other defects.
• Secondary cutting
The next step is granite slabs will be delivered to secondary cutting.
Secondary cutting is an operating unit which is useful for cutting the granite slabs
into desired size, which are 60x60 cm and 100x100 cm.
• Applying epoxy resin
After passing secondary cutting, the granite will be applied by epoxy resin.
Granite stones are very hard but sometimes they contain miniature cracks,
microscopic holes, and some other defects. The defects will lessen the beauty and
durability of the stone. So, epoxy resin is applied to cure these structural defects. It
is applied by automatic resin line machine. After cutting, granite slabs with
microscopic defects are treated with resin using this machine. Granite slabs are
heated inside this machine. Once they came out, the epoxy resin is applied
uniformly on the surface and sent back into the machine where the get heated again
and the structural defects are corrected which increases their durability.
• Applying polyurethane
After applying epoxy resins, the granite will also be applied by polyurethane.
Polyurethane is made by weighting and mixing Polyether polyol HSH220,
HSH330, 1,4-butanediol (BDO), Dibutyltin dilaurate (DBTL), Dimetyl benzene,
Butyl acetate, and Cyclohexanone. Polyurethane is applied so that the ceramics
floor has self-healing ability.
• Packaging
After passing all of the making process, the ceramics floor will be packed
before being distributed and loaded to the trucks. It will be packed into cardboard
which consist of 4 granite each box.
4.3. Main Process Equipment
4.3.1 Granite Stone Lifting Machine
42
Granite stone lifting machine are the equipment that can utilized to move a
stone with overwhelming weight from one place then onto the next. Stone from the
supplier are lifted using gigantic stone lifting machine so the stone not harmed.
Figure 4. 6 Granite Stone Lifting Machine

(Source: https://www.alibaba.com)
Table 4. 4 Granite Stone Lifting Machine

Specification Information
Price US $20,000
Function Lifting a stone with overwhelming
weight
Voltage 380 V
Frequency 50 Hz
Lifting Speed 5-15m/min
Lifting Length 10m
Lifting Height 6m
Supplier Hanan Nybon Machinery Co., Ltd.
China
4.3.2 The Spreader Bar
The Spreader Bar M1 is specifically designed to make moving multiple pieces
of stone easier and safer. . This Spreader Bar has the ability to roll the slab over.
The slings are suspended on crowned aluminum rollers which can be adjusted from
17 3/8" - 56 3/4" in six inch increment.
43
Figure 4. 7 The Spreader Bar M1

Table 4. 5 Specification Spreader Bar M1

Price US $2
Function Stone slab lifting
Load Capacity 1500 kg
Dimension (L x W x H) 1510x110x930mm
Supplier AUSAVINA COMPANY LIMITED. Binh Duong, Vietnam
4.3.3 Gangsaw Machine
Gangsaw machine is a cutting stone machine that can cut block stones into
several slabs of the same thickness. In making Grand Night products, stone blocks
are cut to 1.8x1.2m and 2x1m in size. In 120 minutes gangsaw machine can produce
400 pieces granite slab.
Figure 4. 8 Gangsaw Machine

44
Table 4. 6 Specification of Gangsaw Machine

Price US $25,000
Function Cutting Edge the Stone
Voltage 380 V
Power 65.7 kWh
Supplier Laizhou Orient Machinery Co., Ltd. Fujian, Shandong, China
4.3.4 Lift Arms Granite Cutting Machine
Lift arms granite cutting machine is a stone cutting machine that can cut
stones into several slabs of the same size. In making the Grand Night this equipment
cuts granite size 1.8x1.2m into 6 parts so that the size of each slab 60x60cm is
obtained and cut granite size 2x1m into 2 parts so that 100x100cm granite slab is
obtained. This tool is equipped with lifting arm so that the removal of the pieces of
stone is easy. Lift arms granite cutting machine in 120 minutes can produce 1200
pcs granite 1.8mx1.2m and 400 pcs granite 2 m x1 m.
Figure 4. 9 Lift Arms Granite Cutting Machine

Table 4. 7 Specification of Lift Arms Granite Cutting Machine

Price US $46,600
Function Stone Cutting Machine
Cutting Accurancy 0.1mm
Voltage 350 V
45
Power 37 kW
Cutting Speed 3.4 m2/min
Dimension (L x W) 3000x2000mm
Supplier Shenyang Head Science & Technology
Corporation. Liaoning, China (Mainland)
4.3.5 Automatic Polishing Machine for Granite
Automatic Polishing Machine, a machine designed for polishing the surface
of stone. In a polishing machine with laps, the workpiece is secured to a workbench
and the polishing is done with a rotating lap mounted on a spindle. The lap moves
with the spindle over the surface of granite stone being polished.
Figure 4. 10 20 T Automatic Polishing Machine

Table 4. 8 Specification of 20 T Automatic Polishing Machine

Price US $57,000
Function Polishing the stone
Power 155 kWh
Polishing Speed 3m/min
Water Consumption 20m3/h
Supplier Fujian Jinjiang Hesheng Machine Co., Ltd. Fujian, China
4.3.6 Superline for Epoxy Resin
46
Superline is a machine for apply or coating the epoxy resin. The unique of
this machine is that the user can keep 2 slabs on a single tray at a time, and the
speciality of the superline is that the upper slab will not slide over the bottom slab
while tray is tilted by the hydraulic trolley. Due to intelligency of automatic heating
control system against the machine occupancy it will gives more production with
less power consumption.
Figure 4. 11 Superline
(Source: https://www.indiamart.com)
Table 4. 9 Specification of Superline

Price US $8,000
Function Coating the epoxy resin
Pre-Heating 6 no
Drying Storage Capacity Resin 12 no
Maximum Production 8 – 10 no
Total Installed Power 41 kw
Average Consumption of Power 16 kwn
Supplier Shri Bhagwati Machine Private Limited. Rajasthan, India
(Source: https://www.indiamart.com)
4.3.7 Digital Bench Weighing Scale
Digital bench weighing scale is scales that can measure objects up to a load
of 150kg. The accuracy of this digital scale is 5 grams. From the name of the
product, this scale is measured digitally. To making Grand Night products, these
47
scales are used to weigh raw materials such as polyurethane, epoxy resins, and
others.
Figure 4. 12 Digital Bench Weighing Scale

Table 4. 10 Specification of Digital Bench Weighing Scale

Price US $15
Function Weighing raw material
Capacity 150 kg
Accurancy 5 gram
Dimension (L x W) 3000 x 4000mm
Supplier Yongkang Huaying Weighing Apparatus Co., Ltd. China
4.3.8 Stirred Tank Reactor CSTR
Stirred tank reactor is a tank with an agitator that will combine or mix raw
material in the form of liquid or solid into homogenous mixture in every part.
Stirred tank reactor is equipped with heating bar that can be set to reach the
optimum temperature for mixing process. In making Polyurethane, 3 of this
equipment is used. The mixing tanks specifications and illustration are shown
below.
48
Figure 4. 13 Stirred Tank Reactor CSTR

Table 4. 11 Specification of Stirred Tank Reactor CSTR

Price US $12,000
Function Mixing the Substance
Voltage 220 V
Power 11 kWh
Mixing Type Paddle Mixer
Stirring Speed 60 rpm
Dimension (L x W x H) 5500*2200*2250mm
Supplier Guangzhou Jinghu Mechanical And
Electrical Equipment Co., Ltd.
Guangdong, China (Mainland)
4.4. Mass and Energy Balance Determining Performance
4.4.1 Mass Balance
After the basis of calculation of mass balance is one day production. The mass
balance calculation is used to find out the production performance regarding the
material input as ingredient and material output as product. Before the calculation,
some information will be used to count how many products are produced in one day
production.
49
Table 4. 12 Mass Balance Calculation Basis and Information

Indicator of Measurement Value Unit
Basis 1 day
832 m2/day
Production capacity
1600 pcs/day
Number of batch per day 3
300 days/year
Operating time 8 hours/batch
24 hours/day
The mass balance calculation is proceeded on each unit equipment with the
assumption of 5% mass loss during mixing operation and 2% mass loss during
applying operation. The mass balance calculation is tabulated below.
Table 4. 13 Mass Balance Calculation
Input Output
Unit Process Material
(kg/day) (kg/day)
Polyether polyol HSH220 (40 gram) 16.05 -
Polyether polyol HSH330 (4 gram) 1.78 -
Mixing 1
TDI 7.65 -
A 25.48
Total 25.48
1.4-Butanediol (BDO) 1.81 -
Dibutyltin dilaurate (DBTDL) 1.81 -
Mixing 2
A 25.48 -
B (TDI mixture) 29.09
Total 29.09
Mixing 3 B (TDI mixture) 29.09 -
Dimethylbenzene 19.11 -
Butyl acetate 19.11 -
Cyclohexanone 9.56 -
C (TDI Polyurethane) - 76.88
Total 76.88
50
Table 4.13 Mass Balance Calculation (continued)
Input Output
Unit Process Material
(kg/day) (kg/day)
Mass loss (5%) 3.84
Total After Mass Loss (5%) 73.03
Epoxy resin 0.26 kg/m2
Applying 1 Epoxy needs 215.49 kg/day
Needs after mass loss (2%) 219.80 kg/day
Polyurethane
Applying 2 Polyurethane needs 69.56 kg/day
Needs if mass loss (2%) 70.95 kg/day
From the calculation, the overall ingredient input and product output on daily basis
can be calculated as follow.
• Overall ingredient input = 76.88 kg
• Overall product output = 73.03 kg
4.4.2 Energy Balance
Energy consumption calculation is needed to determine how much energy
will be required to manufacture the product. The assumption is needed for
calculation that the power stated in the equipment specification is the actual power
consumed in the form of electricity. The efficiency of each equipment is taken to
be 85%. The calculation of energy is tabulated below.
51
Table 4. 14 Energy Consumption Calculation

Energy Working Energy Energy Supplied
Qua
No Equipment Consumed per Time Requiremen Losses Energy Source
ntity
Hour (kW) (hour) t kWh kW kW
Granite Stone
1 lifting 1 0.13 1.50 0.19 0.03 0.22 PLN
machine
The Spreader
2 1 0.13 0.50 0.06 0.01 0.07 PLN
Bar
Gang saw
3 1 2.74 6.00 16.43 2.46 18.89 PLN
Machine
Lift Arms
Granite
4 2 3.08 6.00 18.50 2.78 21.28 PLN
Cutting
Machine
Automatic
polishing
5 1 6.46 6.00 38.75 5.81 44.56 PLN
machine for
granite
Automatic
6 polyurethane 1 6.46 4.50 29.06 4.36 33.42 PLN
line machine
Superline for
7 1 1.71 6.00 10.25 1.54 11.79 PLN
Epoxy resin
Digital Bench
8 Weighing 1 0.17 1.50 0.25 0.04 0.29 PLN
scale
9 CSTR 3 1.38 1.00 1.38 0.21 1.58 PLN
Total Energy
114.86 17.23 132.09
Consumed
4.5. Performance Matrics
4.5.1 Throughput time
52
Throughput time is average amount of time product takes to move through

the system. Throughput time can be calculated by adding operating time, inspection
time, move time and queue time. This plant is with 3 batch to make the products
and it takes 8 hours per batch. Inspection time or quality control time is the amount
of time to ensure the quality of the product. It takes approximately 2 hours per batch.
Move time is the amount of time required to move materials or partially completed
products from one workstation to other workstation. It takes 2,67 hours per batch.
Queue time is the amount of time for products waiting to be worked on, moved,
inspected, or shipped. Queue time will be varied according to the manufacture is
held. The maximum queue time is 7 days to be distributed.
𝑇ℎ𝑟𝑜𝑢𝑔ℎ𝑝𝑢𝑡 𝑡𝑖𝑚𝑒 = 24 + 2 + 2,67 + 168 = 196,67 ℎ𝑜𝑢𝑟𝑠
4.5.2 Process velocity
Process velocity is a measure of wasted time in the system.
𝑇ℎ𝑟𝑜𝑢𝑔ℎ𝑝𝑢𝑡 𝑡𝑖𝑚𝑒 196,67 ℎ𝑜𝑢𝑟𝑠
𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = = 8,19
𝑉𝑎𝑙𝑢𝑒 − 𝑎𝑑𝑑𝑒𝑑 𝑡𝑖𝑚𝑒 24 ℎ𝑜𝑢𝑟𝑠
4.5.3 Productivity
Productivity is a measure of how well a company uses its resources
𝑂𝑢𝑡𝑝𝑢𝑡 73,03 𝑘𝑔 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑘𝑔 𝑝𝑟𝑜𝑑𝑢𝑐𝑡
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = = = 0,95
𝐼𝑛𝑝𝑢𝑡 76,88 𝑘𝑔 𝑖𝑛𝑔𝑟𝑒𝑑𝑖𝑒𝑛𝑡 𝑘𝑔 𝑖𝑛𝑔𝑟𝑒𝑑𝑖𝑒𝑛𝑡
4.5.4 Energy Utilization
Energy utilization is a measure of the total energy used to manufacture the
products.
𝐸𝑛𝑒𝑟𝑔𝑦 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 114.86 𝑘𝑊ℎ 𝑘𝑊ℎ
𝐸𝑛𝑒𝑟𝑔𝑦 𝑢𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 = = = 0.07
𝑂𝑢𝑡𝑝𝑢𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 1600 𝑝𝑐𝑠 𝑝𝑐𝑠
4.6. Plant Scheduling
Scheduling is a vital part of running a plant, because it is related to the time
needed to conduct a manufacturing process, so that the manufacturing process must
runs smoothly in the most optimized way. The ceramics floor production process
in carried out in batch mode of operation. There are several stages of production
process, including the start-up stage to set up the unit, the preparation stage to
loading the raw material into the equipment, and so on. First the duration of each
process per one cycle must be calculated. The production process for granite tiles
with self-healing agent takes place as a batch process with 3 batch a day and need
53
480 minutes or 8 hours for each batch process and for production process of
polyurethane as self-healing agent takes place as a batch process with 1 batch a day
and need 270 minutes or 4 hours 30 minutes for production. The total production
process would take around 24 hours with processes broken down from granite
blocks to granite slabs, polishing, cut the granite slab according to the desired size,
applying resin, applying polyurethane, and packaging.
4.6.1 Primary Cutting
Primary Cutting will take about 30 minutes to load the granite blocks into
primary cutting machine, 120 minutes to cut the granite blocks into granite slabs,
and 10 minutes to transfer the granite slabs from primary cutting machine to
polishing machine.
4.6.2 Polishing
Polishing process will take about 10 minutes to load the granite slabs from
primary cutting machine, 120 minutes to polishing process, then secondary cutting
is carried out in parallel after 30 minutes of polishing.
4.6.3 Secondary Cutting
Secondary cutting is carried out in parallel after 30 minutes of polishing.
Secondary Cutting will take about 120 minutes to cut the granite slabs into the
desired size, and then applying epoxy resin is carried out in parallel after 80 minutes
of secondary cutting.
4.6.4 Applying Epoxy Resin
Applying epoxy resin will take about 120 minutes to preparation (because it’s
parallel mode) before its used, 120 minutes to applying epoxy resin process and
heating process for the granite tiles after applying epoxy resin. The heating process
is used to speed up the process.
4.6.5 Weighting (Polyurethane production process)
Polyether polyol weighting will take about 10 minutes to load polyether
polyol, 30 minutes to weighting, and 10 minutes to transfer into polyurethane
primary mixing machine.
4.6.6 Polyurethane Primary Mixing (Polyurethane production process)
54
Polyurethane primary mixing will take about 10 minutes to load the rest of
raw materials, 60 minutes to mixing process, and 10 minutes to transfer from
primary mixing machine to secondary mixing machine.
4.6.7 Polyurethane Secondary Mixing (Polyurethane production process)
Polyurethane secondary mixing will take 10 minutes to load the sample from
primary mixing, 60 minutes to mixing process, and 10 minutes to transfer from
secondary machine to final mixing machine.
4.6.8 Polyurethane Final Mixing (Polyurethane production process)
Polyurethane final mixing will take 10 minutes to load the sample from
secondary mixing, 60 minutes to mixing process, and 10 minutes to transfer from
final mixing machine to quality control room.
4.6.9 Applying Polyurethane
Applying polyurethane as self-healing agent will take about 10 minutes to
preparation before its used, 90 minutes to applying polyurethane process, and 10
minutes to transfer the granite tiles to production checking area.
4.6.10 Primary Packaging
Primary packaging will take about 480 minutes (in parallel mode) to process
after the granite tiles are ready packaged. In each operating day, there are 3 batches
conducted, where the first batch starts at 7.00 a.m., the second batch starts at 15.00
p.m., the third batch starts at 23.00 p.m., and for polyurethane production process
starts at 7.20 a.m. Through the chart, it can be seen that the second batch starts after
the first batch finishes production checking, for change of each batch have duration
about 15 minutes to preparation, and several process can be doing in parallel mode
of operation. The main reason is the expectation to maximize the performance of
the workers, with the attempt to minimize the unproductive time of the workers.
The addition of initial preparation and final cleaning and equipment checking, the
overall operating time on daily basis is 24 hours. Through this amount of time,
around 1600 pcs granite tiles of Grand Night is produced. The scheduling is
illustrated as follow.
55
Figure 4. 14 Plant Scheduling on Daily Basis (1st Batch)
Figure 4. 15 Plant Scheduling on Daily Basis (2nd Batch)
56
Figure 4. 16 Plant Scheduling on Daily Basis (3rd Batch)
57
4.7. Plant Location and Layout

4.7.1 Plant Location
Plant location is very important factor to make the manufacturing process
more efficient. In deciding the plant location, we have to consider both access to
market or distribution cost and access to raw material. Besides, other factors also
need to be considered to establish a factory that is safe and durable. The analysis of
each factors is described below.
4.7.1.1 Availability of Raw Materials
One of the most important considerations involved in selection of industrial
location has been the availability of raw materials required. The biggest advantage
of availability of raw material at the location of industry is that it involves less cost
in terms of transportation cost. In granite industry, raw material needed are granite
rocks which is widely available in Sumatra.
4.7.1.2 Proximity to Market
An industry cannot be thought of without market. When market is far away
from production plant, it will add more transportation cost and reducing profit.
Also, with the lessened difficulty of sending shipment, a higher frequency of
shipping can be done to areas with many customers. In case of goods for export,
availability of processing facilities gains importance in deciding the location of
one’s industry.
4.7.1.3 Infrastructural Facilities
The infrastructural facilities include power, transport and communication,
water, banking, etc. In granite industry, electrical power is a very crucial facilities
because most of the process are using heavy equipment which using high current.
4.7.1.4 Government Policy
Local government regulations are one of the most important factors because
the construction of factories requires permits that go through many stages. if
regulations are not observed, there will be many obstacles in the factory
construction process. Other than that, in order to promote the balanced regional
development, the Government also offers several incentives, concessions, tax
holidays for number of years, to attract the entrepreneurs that can support the
industry.
58
4.7.1.5 Availability of Human Resources

Availability of required manpower is another deciding factor for the location.
Human resources are still the main elements that monitor the entire system of the
plant in ensuring production, as well as performing regular maintenance check.
Therefore, a plant needs skilled labors both as crude labor and office workers.
Cheaper cost of labor can be obtained from backward areas of the industry, but
higher cost of their training also will be obtained
4.7.1.6 Ecological and Environmental Factors
In case of water and air pollution that may happen, the industries which are
likely to damage the ecology and environment of an area will not be established in
settlements. The Government will not grant permission to the entrepreneurs to
establish such industries in such ecologically and environmentally sensitive areas.
There are still more factors that must be considered additionally, among them are
- Competition to another brand
- Incentives, land costs, subsidies for backward areas
- Climatic conditions
- Political conditions
After considering those factors above, authors decided to choose Cilegon
Industrial area as the plant location. It gives secure manufacturing activities such as
electrical, water, human resources, road access and port access. The size of the land
reach 25000 m2 area as seen on the figure below, but it has several land certificates
so that it can be purchased for an area of 4800 m2 with a size of 80x60 m. It is
located precisely on Jalan Raya Bojonegara. The land price reaches Rp
2.000.000,00 per square metric. The reasons why this location is chosen will be
detailly described below.
a. Accessibility to raw materials and electrical power
Plant location in Cilegon makes it easier to access raw materials from
Sumatra, precisely from PT Wira Penta Kencana and PT Kreasi Indah Sahabat.
Other materials which obtained from China can also be delivered easily due to
strategic location. The location of the factory is near Merak Port so the delivery of
raw materials can be done easily and the cost can be cheaper. Besides, the plant is
59
also near Krakatau volcano area so there will be many igneous rocks available, even
though it is still dominated by mines in Sumatra.
b. Accessibility to market
Target market of these granite is mostly dominated in Java because of the
huge construction which being carried out in accordance with the government
projects, also material store that is widely available there. The location of the plant
in Java facilitates the distribution of the products to the development area which
also located in the island of Java. Ease of distribution is supported by the location
which is near to East Cilegon Toll (approximately 2 km away), located at one of
famous industrial area so that truck can be accessed easily, and it is located near
Merak port.
c. Local labor forces
The area surrounding our land is populated with villages and small towns.
This translates to a local labor forces that can be employed to work in our factory,
without having to pay for transportation fee and with a lower pay. Furthermore,
there are housing complexes about 30 to 50 m from the factory, this allows skilled
labors such as engineers, supervisors, technician, and such to live in the nearby
dormitory without having to keep commuting to work. This also helps ease the
burden of the engineers’ work load. In addition, there are several food stalls and
material store across the land so that plant construction can prosper the surrounding
community.
Figure 4. 17 Location of Granite Floor Plant

(Source: Google Earth, 2019)
60
Figure 4. 18 Granite Plant Street View

(Source: Google Street View, 2019)
4.7.2 Plant Layout
Plant layout is the most effective physical arrangement, either existing or in
plans of industrial facilities i.e. arrangement of machines, processing equipment
and service departments to achieve greatest co-ordination and efficiency of 4 M's
(Men, Materials, Machines and Methods) in a plant. Effective plant layout also
needed to minimize the overall operating cost. In designing plant layout, there are
several steps that needed to be done which described below.
4.7.2.1 Identification of Suitable Process Type
The manufacturing of Grand Night product is a batch type process because of
the small amount of production and the difficulty of the product from equipment to
other equipment and due to the long time of the process that occurs in one tool. In
addition, to support tool efficiency and maintaining the tool to last long, the
equipment is not operated continuously. Batch process means less automation than
the continuous counterpart, which implies to less expenditure on the automation
system. Automation will only seem profitable when the operating time is nearly all-
day long with large amount of production. With two batch per day and 8 hours
working hour per day, product capacity can be fulfilled.
4.7.2.2 Selection of Suitable Layout Type
Keeping in view the type of industry and the production capacity, the type of
layout to be selected is classified into product layout and process layout. In product
layout, the machines and equipment are arranged in one line depending upon the
61
sequence of operations required for the product. It is also called as line layout. The
material moves to another machine sequentially without any backtracking or
deviation i.e. the output of one machine becomes input of the next machine. This
type is used for mass production of standardized products or product that need
quality control periodically.
In process layout type, the machines of a similar type are arranged together at
one place. This type of layout is used for batch production. It is preferred when the
product is not standardized and the quantity produced is very small. There is also a
combination of process and product layout known as combined layout. Based on
the granite product, product layout is chosen because the goods are standardized
and need quality control but it is produced in big capacity, and the machineries are
in sequential or series arrangements. The coordination and production planning and
control is simpler. Less skilled workers may serve the purpose, but training for
workers is still needed to maintain the good quality products.
4.7.2.3 Making a detailed layout
Table 4. 15 Plant Area Estimation
Room Length / radius (m) Width (m) Area (m2)
Building
Office Lot 15 10 150
Security Post 3 3 9
Product Storage 20 10 200
Polyurethane Ingredients 10 5 50
Storage
Production Area 50 20 735
Total Area 1162
Non-building
Parking Lot 10 10 100
Raw Material Storage 32 8 256
Emergency Evacuation 4 - 12.56
Zone
Total Area 368.56
62
= Production line
Figure 4. 19 Plant Layout
63
CHAPTER 5
SUPPLY CHAIN
5.1 Logistics of Raw Materials

5.1.1 Raw Material Supply
Raw material supply is an essential part of an ongoing and efficient
productivity for production. Raw material need to make Grand Night product are
granite rocks, epoxy resin, dimethylbenzene, butyl acetate, cyclohexanone, 1,4-
butanediol (BDO), dibutylin dilaurate (DBTDL), toluene diisocynate, polyether
polyol HSH220, polyether polyol HSH330, and cardboard box for packaging.
It is agreed to have two different suppliers for emergency and increasing
product demand. To select suppliers, reasons which are considered are quality of
material, price, location. However, for quality we are not going to bargain more if
the supplier cannot give according to manufacturing needs. Thus, two of the
suppliers have the same quality of material, but a possible different price and
location. The first and second suppliers with their properties are listed in
Appendices A
5.1.2 Raw Material Order Capacity
Having the raw material supplier on notes, next manufacturer can determine
the order capacity. Several factors are considered on how to determine the order
capacity. Those factors are minimum order, amount of order per year, amount of
package per order, delivery cost, and safety inventory. To determine the amount of
order per year, minimum order and amount of package per order needed to be paid
attention at. This is to determine the lowest cost for delivery. Additionally, a 20%
of all the material needed is also ordered as safety inventory. In Appendices B there
are the calculation of price and amount of order of raw material.
5.1.3 Raw Material Inventory
The amounts of raw material are decreasing by manufacture process. To
keep the raw material in sufficient amount so the manufacture process stable, the
inventory of raw material must be done. In addition, inventory influences the
company’s economic cycle. Holding large amounts of inventory allows a company
or an entire supply chain to be very responsive to fluctuations in customer demand.
64
However, the creation and storage of inventory is a cost and to achieve high levels
of efficiency, the cost of inventory should be kept as low as possible.
The inventory of raw material is decided by fixed order quantity method in
the previous subchapter, and the condition of raw material are presented below.
Raw Material Inventory Chart

6000 160000
140000
5000
120000
4000
100000
Mass (kg)
Axis Title
3000 80000
60000
2000
40000
1000
20000
0 0
0 50 100 150 200 250 300
Day
A C D E F G H I J B K
Figure 5. 1 Raw Material Inventory Chart per day
5.2 Product Distribution and Inventory

5.2.1 Product Distribution Location and Pathway
Grand Night will be distributed to 7 cities in Indonesia which is located in
Java and Sumatra. These cities were chosen due to the high city development index.
Distribution is calculated based on the number of exist and upcoming tall buildings
above 7 floors which represent number of constructions in the city. Based on
amount production product per week is 1800 boxes of 60x60 cm2 granite plus 600
boxes of 100x100 cm2 granite:
65
Table 5. 1Product Distribution Location and Capacity

Granite 100x100 Granite 60x60
Number
Percentage cm2 distribution cm2 distribution
City of Tall
(%) per delivery time per delivery time
Buildings
(boxes/week) (boxes/week)
Kab. 18 0.020 12 36
Tangerang
Bekasi 13 0.015 9 26
Bandung 163 0.183 110 329
DKI 393 0.441 264 793
Jakarta
Depok 15 0.017 10 30
Semarang 151 0.169 102 305
Palembang 139 0.156 93 280
(Sumatera)
TOTAL 892 1 600 1800
The main customers of Grand Night are the owner of public spaces, public
facilities and office. Therefore, the products will be distributed to retailers around
the city which are material stores that are quite large. Distribution of the products
will be divided into 5 pathways:
• Lane I : Tangerang, Depok, Bekasi
• Lane II : DKI Jakarta
• Lane III : Bandung
• Lane IV : Semarang
• Lane V : Sumatra Island (Palembang)
Lane V use freight forwarding service from Merak Port to Bakauheni Port
due to more economic expense. Other lane uses land line. Detailed pathway will be
described in Table 5.2 Selection of this distribution pathway based on the shortest
distance to be more economical and time efficient.
66
Table 5. 2 Product Distribution Pathway

Distance to
Total Total
Distance each Time
Lane From To distance time
(km) material (hr)
(km) (hr)
store (km)
Plant Tangerang 83 20 103 2.8
Lane
I Tangerang Depok 47 15 62 3.9
12.8
Depok Bekasi 42 20 62 3.6
Bekasi Plant 119 0 119 2.5
Lane Plant DKI Jakarta 99 50 149 7.3
9.3
II DKI Jakarta Plant 99 0 99 2.0
Lane Plant Bandung 246 20 266 11.0
18.0
III Bandung Plant 246 0 246 7.0
Lane Plant Semarang 537 20 557 12.0
22.0
IV Semarang Plant 537 0 537 10.0
Plant Merak Port 21 0 21 0.7
Lane Merak Port Bakauheni Port 34 (water) 0 34 2.0
V
Bakauheni Port Palembang 450 30 480 15.0
31.7
Palembang Bakauheni Port 450 0 450 12.0
Bakauheni Port Merak Port 34 (water) 0 34 2.0
Merak Port Plant 21 0 21 0.7
5.2.2 Product Inventory
In the supply chain, inventory review is important to discuss in order to
predict how much stock of raw materials and products can be stored. It is also
important because it relates to the ability of the producers to meet the market
demand at any given time. Fluctuations projection is made using several
assumptions, which are :
1. Production is carried out with a capacity of 100%.
2. Delivery is distributed to destination done every week but still depends on
distribution proportion based on previous section.
3. Delivery from factory to directly to store buildings in some places spread in :
DKI Jakarta, Tangerang, Bekasi, Depok, Bandung, Semarang, and Palembang.
Delivery to each city is determined using percentage number of tall buildings in
every city. The city which number of tall building is higher will be delivered more
ceramics floor.
67
Table 5. 3 Storage Inventory

Total Products in
Month Weeks Area I Area II Area III Area IV Area V
Warehouse (boxes)
1 780 124 1057 439 0 0

2 1560 124 1057 439 0 0
1
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
2
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
3
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
4
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
5
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
6
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
7
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
68
Table 5.3 Storage Inventory (continued)

Total Products in
Month Weeks Area I Area II Area III Area IV Area V
Warehouse (boxes)
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
8
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
9
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
10
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
11
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
1 1594 124 1057 439 0 746
2 1560 124 1057 439 814 0
12
3 1594 124 1057 439 0 746
4 1560 124 1057 439 814 0
5.2.3 Mode of Transportation
The distribution of the product will use the truck as land transportation. The
used trucks are Mitsubishi Colt Diesel Double (CDD) and Mitsubishi Fuso Tronton
Box, for transportation to DKI Jakarta, Tangerang, Bekasi, Depok, Bandung,
Semarang and Palembang. The trucks use solar as fuel. One liter of solar can travel
a distance of 10 km. The price of diesel is Rp 5,150 per liter. The specification of
the truck shows in Table 5.4.
69
Table 5. 4 Specification and Price of the Truck

Volume Weight Price
Qty Truck Type
(m3) (ton) (IDR)/unit
Mitsubishi
Colt 24,64
2 8 266,700,000
Diesel m3
Double
Mitsubishi
Fuso 31,88
3 15 520,000,000
Tronton m3
box
5.3 Marketing Strategy

To make grand night products known to the public and purchased by
customers, several marketing strategies must be carried out. The steps that will be
carried out by Grand Night include promotion online and offline.
a) Online strategy
Online strategy is done by creating websites and social media. Website and
social media can help buyers to access catalogue, get to know company profiles,
find out about new product developments, and contact companies for purchasing
and other requests.
b) Offline strategy
Offline strategy is done by spreading catalogs that are deposited in each material
store, employing sales in large material stores, and installing banners and billboards
that can attract the attention of buyers. In addition, direct promotions are also
carried out by participating in exhibitions and ceramics conferences if available.
This can increase the company relation.
70
CHAPTER 6
ECONOMICS
6.1 Total Capital Investment

Capital investment refers to money used by a business to purchase fixed assets,
such as land, machinery, or buildings. This investment will be purchased once in the
beginning of the company. Capital investment can be gained either through investors
or investment banks. In doing estimation of capital investment, there are several
assumptions which are
• The plant construction will start in the beginning of 2020.
• The manufacturing process is expected to be operating in the beginning of 2021
with plant life span of 10 years.
• The exchange rate of currency is assumed at IDR 14,273 / 1 USD per May 3rd
2019.
• The plant will run for 300 days per year with an average of 6 days per week.
• The production capacity of Grand Night is 832 m2 per day or 400 boxes per
day (including 60x60 cm2 and 100x100 cm2 type), and 2400 boxes per week
in accordance with the distribution of products which made every week.
Total capital investment is the amount of all costs incurred to design, build and
start production. total capital investment consists of fixed-capital investment and
working-capital investment. Fixed-capital investment (FC) is a capital to design and
build a factory that is ready to be started up. This fee is usually paid to the contractor
and recovered after several years using depreciation cost. FC consist of direct and
indirect cost which will be described further in the next section. Meanwhile, working-
capital investment is a capital needed to start production (manufacturing costs in the
initial weeks of production until income is obtained). The calculation of total capital
investment is using Modular Guthrie Method with formula:
𝐶𝑇𝐶𝐼 = 𝐶𝐹𝐶 + 𝐶𝑊𝐶
𝐶𝑇𝐶𝐼 = 𝐶𝑑𝑖𝑟𝑒𝑐𝑡 + 𝐶𝑖𝑛𝑑𝑖𝑟𝑒𝑐𝑡 + 𝐶𝑊𝐶
71
𝐶𝑇𝐶𝐼 = 1.18(𝐶𝑇𝐵𝑀 + 𝐶𝑠𝑖𝑡𝑒 + 𝐶𝑏𝑢𝑖𝑙𝑑𝑖𝑛𝑔𝑠 + 𝐶𝑜𝑓𝑓𝑠𝑖𝑡𝑒 𝑓𝑎𝑐𝑖𝑙𝑖𝑡𝑖𝑒𝑠 ) + 𝐶𝑊𝐶

Where
𝐶𝑇𝐶𝐼 = total capital investment
𝐶𝐹𝐶 = fixed capital
𝐶𝑊𝐶 = working capital
𝐶𝑑𝑖𝑟𝑒𝑐𝑡 = direct cost
𝐶𝑖𝑛𝑑𝑖𝑟𝑒𝑐𝑡 = indirect cost (usually 0.18 x direct cost)
𝐶𝑇𝐵𝑀 = total bare module cost
𝐶𝑠𝑖𝑡𝑒 = site development cost
𝐶𝑏𝑢𝑖𝑙𝑑𝑖𝑛𝑔 = building cost
𝐶𝑜𝑓𝑓𝑠𝑖𝑡𝑒 𝑓𝑎𝑐𝑖𝑙𝑖𝑡𝑖𝑒𝑠 = offsite facilities cost
Each component should be calculated separately to get the total capital
investment using Modular Guthrie method.
6.1.1. Fixed Capital
6.1.1.1.Direct Cost
Direct cost consists of equipment cost, land cost, building cost, supporting
facilities cost, utility installation cost, market research cost, also patent, industrial
design, and brand cost.
A. Equipment Cost
Equipment cost is the cost needed to get the equipment until it can be operated
normally in manufacturing process. To get the equipment cost, Free on Board (FOB)
price must be known. Free on Board (FOB) is a contractual term that refers to the
requirement that the seller deliver goods at the seller's cost via a specific route to a
destination designated by the buyer. Equipment price which obtained from trading
website, for example Alibaba, is already FOB price. If the equipment is delivered
through freight forwarding, FOB price is the cost needed until the equipment is
delivered to the nearest port of supplier. After that, all cost is borne by the buyers.
𝐼𝑛𝑑𝑒𝑥 𝑣𝑎𝑙𝑢𝑒 𝑎𝑡 𝑝𝑟𝑒𝑠𝑒𝑛𝑡 𝑡𝑖𝑚𝑒
𝑃𝑟𝑒𝑠𝑒𝑛𝑡 𝑐𝑜𝑠𝑡 = 𝑂𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑐𝑜𝑠𝑡 ( )
𝐼𝑛𝑑𝑒𝑥 𝑣𝑎𝑙𝑢𝑒 𝑜𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑐𝑜𝑠𝑡 𝑜𝑏𝑡𝑎𝑖𝑛𝑒𝑑
72
Index value at present time will be extrapolated from linear regression equation
obtained from the data of M&S Index Value from 1999 to 2013.
M&S Index Value

1800
1600
1400
M&S Index Value
1200 y = 46.01x - 90976

1000 R² = 0.9667
800
600
400
200
0
1998 2000 2002 2004 2006 2008 2010 2012 2014
Year
Figure 6. A Curve of Marshall & Swift Index Value
From the curve, the mathematical model of M&S Index Value can be
formulated as follow.
𝐼𝑛𝑑𝑒𝑥 𝑣𝑎𝑙𝑢𝑒 = 46.01 𝑌𝑒𝑎𝑟 − 90976
Therefore, the M&S Index Value of year 2019 (now) and 2020 can be obtained by
substitute the year to formulation
Table 6. 1 Forecasting Marshall & Swift Index Value
Year M&S Index Value
2019 1918.19
2020 1964.2
After this, the price of equipment in year 2019 can be estimated by the price of
equipment gotten in 2018 which listed in Table 6.2.
73
Table 6. 2 FOB Price of All Equipment

FOB price in 2019 FOB price in 2020
Equipment
USD IDR USD IDR
Granite stone lifting machine $ 20,000 IDR 285,460,000 $ 20,480 IDR 292,307,087
The Spreader bar $1 IDR 14,273 $1 IDR 14,615
Gangsaw Machine $ 25,000 IDR 356,825,000 $ 25,600 IDR 365,383,859
Lift arms granite cutting $ 46,000 IDR 656,558,000 $ 47,103 IDR 672,306,301
machine
Automatic polishing machine for $ 58,000 IDR 827,834,000 $ 59,391 IDR 847,690,553
granite
Superline for epoxy resin $ 48,000 IDR 685,104,000 $ 49,151 IDR 701,537,010
Digital bench weighing scale $ 140 IDR 2,000,000 $ 143 IDR 2,047,972
Stirred tank reactor CSTR $ 12,000 IDR 171,276,000 $ 12,288 IDR 175,384,252
Stainless steel single-layer $ 1,500 IDR 21,409,500 $ 1,536 IDR 21,932,032

storage tank
The FOB price will be adjusted in order to get the total cost needed until the
equipment can operate normally. A term bare module factor provides an estimation of
FOB price plus all factors needed such as piping, instrumentation, electrical, painting,
and additional components. The shipping cost is obtained from Shenzhen Uni-Home
International Logistics Co., Ltd which is the sea freight shipping agent from China.
However, all the equipment is already sets when arrived at the plant and the bare
module factor values 1. Shipping cost is $ 10 / m3 from China and $ 1554 / 40 ft
container from India (tax included). The adjusted cost of all equipment which have
considered bare module factor is tabulated in Table 6.3.
74
Table 6. 3 Adjusted Cost of All Equipment
Bare
FOB Price in 2020 Supplier Shipping Cost Adjusted Cost
Equipment Quantity Modul
(IDR) Location (IDR) (IDR)
Factor
Granite stone lifting machine IDR 292,307,087 1 China 1 IDR 2,283,680 IDR 294,590,767
The spreader bar IDR 14,615 1 Indonesia 1 IDR - IDR 14,615
Gangsaw Machine IDR 365,383,859 1 China 1 IDR 27,727,772 IDR 393,111,632
Lift arms granite cutting
machine IDR 672,306,301 2 China 1 IDR 685,104 IDR 1,345,982,810
Automatic polishing machine
for granite IDR 847,690,553 1 China 1 IDR 4,438,789 IDR 852,129,342
Superline for epoxy resin
IDR 701,537,010 1 India 1 IDR 22,180,242 IDR 723,717,252
Digital bench weighing scale IDR 2,047,972 1 Indonesia 1 IDR - IDR 2,047,972
Stirred tank reactor (CSTR)
100 L IDR 175,384,252 3 China 1 IDR 113,612 IDR 526,493,592
Stainless steel single-layer
storage tank IDR 21,932,032 1 China 1 IDR 215,808 IDR 22,138,839
TOTAL EQUIPMENT COST IDR 4,160,226,822
75
B. Land and Building Cost

The plant will operate in Cilegon industrial area in Cikarang with the total area
of 4800 m2 with a size 80x6m. It is located precisely on Jalan Raya Bojonegara. The
land price reaches Rp 2,000,000.00 per square metric. The buildings are mainly
classified as plant section and office section. The land and building cost is estimated as
follow.
Table 6. 4 Land Cost Estimation
Cost per m2 (IDR) Area (m2) Land Cost (IDR)
IDR 2,000,000 4800 IDR 9,600,000,000
Table 6. 5 Plant Area Cost Estimation

Building Cost
Description Cost per m2 (IDR) Area (m2)
(IDR)
Office Section IDR 3,000,000 168 IDR 504,000,000
Plant Section IDR 2,500,000 1250 IDR 3,125,000,000
Parking Lot and IDR 195,000 112.56 IDR 21,888,750
Emergency Zone
TOTAL BUILDING COST 3,650,949,200
(Source: Sartala, 2012, reproduced)
C. Supporting Facilities Cost
Supporting facilities refer to necessary supporting installation and equipment
that are not included within the main production section and therefore need to be
calculated separately. The estimation of supporting facilities cost is tabulated as follow.
76
Table 6. 6 Supporting Facilities Cost Estimation
Total Cost
Equipment Specification Source Qty Price (IDR)
(IDR)
General Section
Mitsubishi Colt diesel FE 84G Bus Chasis 136
Cargo Truck Otomaniac 2 266,700,000 533,400,000
PS 6 Ban
Tronton Box Tronton box 6S20 15 ton OLX 3 520,000,000 1,560,000,000
PHILIPS 31093 TrunkLinea 4W 250lm 3000K
LED Lamps Tokopedia 30 59,000 1,770,000
wall lamp LED
Kipas Angin Besi Tornado Typhoon Meja Sekai
Fan Tokopedia 3 110,000 330,000
HFN 650
Dispenser DISPENSER AIR SANEX MODEL D102 Shopee 3 90,000 270,000
Internet Upkeep Fastnet combo Supreme X1 4K 32 Mbps First media 1 709,000 709,000
Interphone Commax TP-1L - 2 way indoor intercom system Tokopedia 1 580,000 580,000
CCTV 8ch full hd brand sony 6 kamera 1080p +
CCTV Set (6 pcs) Tokopedia 1 4,650,000 4,570,000
Hdd 1tb
Fire Extinguisher FireX ABC Fire Extinguisher FX-25 2.5 Kg Monotaro 3 599,000 1,797,000
Green Leaf Bio Tempat Sampah Tutup Goyang
Trash Bin Monotaro 10 149,000 1,490,000
2032 Assorted Color 36L
Green Leaf Bio Tempat Sampah Tutup Goyang
Generator Tokopedia 1 79,300,000 79,300,000
2032 Assorted Color 36L
Plant Section
Filling and Labeling Table Arca Furniture 160x60x75 Bukalapak 1 1,300,000 1,300,000
Packaging Table Arca Furniture 160x60x75 Bukalapak 1 1,300,000 1,300,000
Toilet Stalls toto CW 420J+ SW 420/8 IN+ Tutup TC 505W Tokopedia 5 1,575,000 7,875,000
77
Table 6.6 Supporting Facilities Cost Estimation (Continued)

Equipment Specification Source Qty Price (IDR) Total Cost (IDR)
Production Area Chair OLYMPLAST plastic chair bukalapak 20 45,000 900,000

Forklift Forklift 10 Ton Caterpillar Type DP100 Builtup bukalapak 1 485,000,000 485,000,000
Rack Storage Rak Gudang Heavy Duty Custom bukalapak 3 4,000,000 12,000,000
Office Section
Telephone Panasonic KX-TS505MX Shopee 3 146,500 439,500

Faximailes Panasonic Faximile KX-FP701 Tokopedia 1 1,595,000 1,595,000
Projector Set Epson Projector EB-S400 Shopee 1 4,745,000 4,745,000
Air Conditioner SAMSUNG AR18KRSFW 2PK Tokopedia 2 5,575,000 11,150,000
Desktop Computers Asus AIO V222GAK-BA141T All-In-One Tokopedia 10 4,749,000 47,490,000
Office Chairs Sabaru Daichi Kursi Kantor Blibli 15 665,000 9,975,000
Office Desks Meja MT 122 Tokopedia 10 245,000 2,450,000
Photocopy, Printer and Scanner Epson L3150 Printer EcoTank WiFi [Print, Scan,
Shopee 2 2,680,000 5,360,000
Machine Copy]
Whiteboard Keiko Board Double Face Stand 60*90cm Blibli 1 638,500 638,500
Television LG 32LK500BPTA Digital LED TV [32 Inch] Blibli 1 1,999,000 1,999,000
Filling Cabinet Filling Cabinet 12 doors ML 8812 Shopee 2 4,236,000 8,472,000
Absence Machine Solution P207 Finger Print Blibli 1 555,000 555,000
JYSK Set Toreby 120X70X75CM (1 Table + 4
Mess hall Set Dekoruma 2 2,899,900 5,799,800
Chairs)
78
D. Utility Installation Cost

Installation of utility is needed as technical support to the manufacturing
process. The main utilities in Grand Night manufacturing plant consist of water and
electricity, with additional utilities for telephone and internet.
Table 6. 7 Utility Installation Cost Estimation

Utilities Notes Cost (IDR)
Main Utility
Electricity 15000 VA Industrial 20,000,000
Water PDAM - Industri 15,000,000
Supporting Utility
Telephone Telkom 1,500,000
Internet First Media 500,000
TOTAL UTILITY COST 37,000,000
E. Market Research Cost
The initial research on market is needed to achieve the maximum profit of the
project. To do this, an amount of cost must be expended, and the estimation is
calculated from regulation of Peraturan Presiden No. 16 Tahun 2018 about Goods and
Services. It is tabulated as follow.
Table 6. 8 Market Research Cost

Market Research Activities Price (Rp)
Survey 5,000,000
Consultant Service 25,000,000
Total Market Research Cost 30,000,000
F. Patent, Industrial Design, and Brand Cost
In this section, calculated cost includes patent registration, industrial design,
and brand which is regulated in Peraturan Pemerintah No. 28 Tahun 2019 about Types
and Rates for Non-tax State Revenues that Applicable in The Ministries of Law and
Human Rights.
79
Table 6. 9 Patent, Industrial Design, and Brand Cost Estimation

Type Unit Qty Cost (IDR)
Patent Cost
Patent Request per request 1 800,000
Claim Cost per claim 1 75,000
Request for Priority Right Letter per request 1 300,000
per registration
Compulsory License Request 1 1,000,000
number
Copy of Certificate Request per sheet 1 20,000
Patent Research : (a) Local per subject 1 250,000
Patent Research : (b) Global per subject 1 1,390,000
Total Patent Cost 3,835,000
Industrial Design Cost
Industrial Design Registration per request 1 1,250,000
Industrial Design General List of Quotes
per request 1 400,000
Request
Industrial Design Certificate Publishing
Cost
Industrial Design Priority Document
Request
Industrial Design Copy of Document
Request
per registration
Industrial Design License Administration 1 350,000
number
Total Industrial Design Cost 2,450,000
Brand Cost
Brand Publishing Cost per class 1 1,800,000
Lengthening Time of Brand Protection per request 1 2,500,000
80
Table 6.9 Patent, Industrial Design, and Brand Cost Estimation (continued)
Type Unit Qty Cost (IDR)

Brand Certificate Publishing Cost per request 1 200,000
License Administration per registration 1 500,000
number
Official Brand Quotes Request per request 1 300,000
Written Notes of General List of Brand per request 1 800,000
Request
Total Brand Cost 6,100,000
Total Patent, Industrial Design, and 12,385,000
Brand Cost
6.1.1.2.Indirect Cost
Indirect cost refers to the supporting cost to technical operation includes
engineering and supervision, construction expense, contractor’s fee, and contingency.
However, indirect cost can be calculated from total fixed cost
𝐶𝑖𝑛𝑑𝑖𝑟𝑒𝑐𝑡 = 0.18 𝐶𝐹𝐶
Table 6. 10 Indirect Cost and Total Fixed Cost Calculation
Item Notes Cost (IDR)
Total Direct Cost Equipment + Land and IDR 19,945,641,022
building cost + supporting
facilities + utility installation
+ market research + patent
Total Indirect Cost 18% of Total Fixed Cost IDR 3,590,215,384
Fixed Capital 1.18(Total Direct Cost) IDR 23,535,856,406
6.1.2. Working Capital
Working capital is the cost needed to start the manufacture process in the first
year. It includes all operating cost expended until the project gets the first revenue. The
assumption used for calculation is that the plant will operate in a full one year first
before a first revenue is obtained.
81
Table 6. 11 Working Capital Cost

Expense Type Details Cost (IDR)
Raw material IDR 25,501,520,984
Labor salary IDR 5,013,600,000
Direct production cost
Utility IDR 269,279,512
Maintenance IDR 844,687,994
Local tax IDR 88,534,400
Fixed cost
Insurance IDR 322,569,304
Distribution IDR 707,841,700
General Expense Marketing and
Communication IDR 121,470,000
TOTAL WORKING CAPITAL IDR 32,869,503,895
6.1.3. Total Capital Investment
Total capital investment then can be calculated using Modular Guthrie calculation.
Table 6. 12 Total Capital Investment
Type of Expenses Cost (IDR)
Direct cost
Equipment IDR 4,160,226,822
Land IDR 9,600,000,000
Building IDR 3,650,949,200
Support facilities IDR 2,455,080,000
Utility Installation IDR 37,000,000
Market research IDR 30,000,000
Patent IDR 12,385,000
Total direct cost IDR 19,945,641,022
Indirect cost IDR 3,590,215,384
Total fixed capital IDR 23,535,856,406
Working capital IDR 32,754,665,794
Total capital investment IDR 56,290,522,200
82
6.2 Operational Cost

Operational cost be sub-divided to the costs that are directly proportional to
production rate and costs that are slightly proportional to the production rate (fixed
cost). Direct production cost consists of raw materials, utilities, operating labor, and
supervisory and clerical labor salary, maintenance and waste treatment, and patent,
industrial design, and brand. Fixed cost consists of local tax and insurance. There are
also plant overhead cost and general expenses which will be detailed in the next section.
6.2.1. Direct Production Cost
6.2.1.1.Raw Material
There are eleven raw materials that are needed to be purchased from the
supplier. In order to evaluate the cost, we choose the basis of raw materials cost per
annum. Based on the calculation on Appendices C, the total raw material cost
(including packaging cost) for product with the amount Rp 25,621,540,984 for total
order cost per year and the amount of Rp 879,980,000 for total delivery cost per year.
6.2.1.2.Labor Salary
Determination for the employees’ salary is based on the article published in
Okezone regarding the Regional Minimum Wage Policy. The Regional Minimum
Wage on the province of Cilegon, Banten on 2019 is RP 3,913,078. The calculation of
labor salary is shown below. Based on the calculation, the total cost per year is IDR
5,013,600,000.
Table 6. 13 Labor Salary
Salary per
Amount Total Salary per Total Salary per
Position Month per
(person) Month (IDR) Year (IDR)
Person (IDR)
President Director 1 25,000,000 25,000,000 300,000,000
General Manager 1 20,000,000 20,000,000 240,000,000
Secretary of
1 10,000,000 120,000,000
President Director 10,000,000
Finance
Accounting 1 11,000,000 132,000,000
Manager 11,000,000
Production
1 11,000,000 132,000,000
Manager 11,000,000
Production Staff 5 5,000,000 25,000,000 300,000,000
83
Table 6.13 Labor Salary (continued)
Salary per
Amount Total Salary per Total Salary per
Position Month per
(person) Month (IDR) Year (IDR)
Person (IDR)
Quality Control
1 11,000,000 132,000,000
Manager 11,000,000
Quality Control
2 5,100,000 122,400,000
Staff 10,200,000
Human Resources
1 11,000,000 132,000,000
Manager 11,000,000
Marketing Manager 1 11,000,000 11,000,000 132,000,000
Marketing Staff 3 5,200,000 15,600,000 187,200,000
Driver 5 4,000,000 20,000,000 240,000,000
Security 6 4,000,000 24,000,000 288,000,000
Cleaning Service 6 4,000,000 24,000,000 288,000,000
Production Labor 45 4,200,000 189,000,000 2,268,000,000
Total 80 417,800,000 5,013,600,000
6.2.1.3.Utility
Utility is a supporting system that generates, transmit or distributes basic
necessities that a plant needed in order to run. In this plant, both the production process
and other supporting facilities needs electricity, water, and diesel. For electricity, the
price given by the PT. Perusahaan Listrik Negara (PLN) differs according which type
of the industries. For small to medium business, the plant operated in the I-1/3500 VA
s.d 14 kVA segment. For this segment, the price for electricity is Rp1,112.00/kWh. For
water, the plant is planned to be using water from Perusahaan Daerah Air Minum
(PDAM) Cilegon. The price for industry with usage over 10 m3 is Rp9,500.00/m3.
Lastly, the plant use generator for ¼ its electricity usage with price point of
Rp13,172.22/m3. The total utility cost from Appendices D is shown in table 6.14.
Table 6. 14 Total Utility Cost
Type Cost/year
Equipment Electricity Rp 25,538,915
Supporting Faclities Electricity Rp 14,531,616.00
Water Rp 9,645,198.00
Diesel Rp 219,563,783.51
Total Rp 269,279,512
84
6.2.1.4.Maintenance
Maintenance is amount of money spent to maintain the building and equipment
of the plant in good working condition. Maintenance cost are considered because the
condition of building and equipment is very important in manufacturing sustainability.
The maintenance cost from the literature are 1% of buildings, factory, and warehouses
cost, 3% of supporting facilities cost, and 15% of main production process equipment.
The calculation of maintenance cost gives IDR 734,195,915, shown below.
Table 6. 15 Maintenance Cost
Type Referral Cost (IDR) Maintenance Cost (IDR)
Supporting Facilities Maintenance 2,455,080,000 73,652,400
Factory, Warehouses and Buildings 3,650,949,200 36,509,492
Equipment Maintenance 4,160,226,822 624,034,023
Total 734,195,915
6.2.1.5.Patent Cost
A patent is a right granted to an inventor by the federal government that permits
the inventor to exclude others from making, selling or using the invention for a period
of time. There will be a certain cost that should be paid for every year according to
“Peraturan Pemerintah No. 28 Tahun 2019.” The calculation of patent’s cost will be
use estimated time for the next 2-10 years.
Table 6. 16 Patent Registration Cost for Next Year 2nd-10th
Base Cost Cost per Cost of Claim
Year Total Claim Total Cost (IDR)
(IDR) Claim (IDR) (IDR)
2 750,000 50,000 3 150,000 900,000
3 750,000 50,000 3 150,000 900,000
4 750,000 50,000 3 150,000 900,000
5 1,250,000 50,000 3 150,000 1,400,000
6 1,700,000 50,000 3 150,000 1,850,000
7 2,300,000 50,000 3 150,000 2,450,000
8 2,800,000 50,000 3 150,000 2,950,000
9 3,500,000 50,000 3 150,000 3,650,000
10 4,000,000 50,000 3 150,000 4,150,000
TOTAL PATENT REGISTRATION 19,150,000
85
6.2.2. Fixed Cost

6.2.2.1.Local Tax
Local tax contains property tax and salary tax. The value is calculated using the
method ruled by the law of Indonesia and the law of Cilegon Regency shown below.
Table 6. 17 Cost of Property Tax
Description Total Price (IDR)
NJOB Land Value IDR 9.600.000.000
NJOB Building IDR 3.650.949.200
Total NJOP IDR 13.250.949.200
NJOPTKP IDR 15.000.000
NJOP IDR 13.235.949.200
Debted PBB (0.5% NJOP) IDR 6.617.974.600
Everybody who works need to pay the salary tax suitable with their salary. The
calculation of salary tax in Indonesia is stated in the Peraturan Direktur Jenderal Pajak
No. PER-16/PJ/2016, Peraturan Menteri Keuangan No. 101/PMK.010/2016 and No.
102/PMK.010/2016. The calculation are made with these assumptions:
1. Every taxpayer has a wife and a child, thus the non-taxable income is IDR
63,000,000.
2. Based on BPJS regulation, insurance which is paid by the company is 4% and every
employee is 1% per month.
3. Tax calculation is conducted with progressive system (tax system which is adopted
in Indonesia) based on UU No.36 Tahun 2008 Pasal 17 under income condition as
follows:
Table 6. 18 Tax Income Calculation
Income (IDR) Tax Rate (%)
0-50 million 5%
50 - 250 million 15%
250 - 500 million 25%
>500 million 30%
86
Then, by computing taxable income, it is found that the total income tax per
year is IDR 88,534,400. By assuming up the income tax and the property tax, an
amount of IDR 6,479,678,775 of total local tax can be found.
6.2.2.2.Insurance
The paid insurance includes the insurance for cost of plant and employee’s
insurance. The data for insurance of employees is obtained from Jamsostek (Jaminan
Sosial Tenaga Kerja). It is said that the company should pay at least 4% of the worker
wages monthly to follow this insurance program. The program includes old age
insurance program, work accident insurance program, death insurance program.
Table 6. 19 Insurance Calculation
Insurance Type Measurement Amount (IDR) Annual Cost (IDR)
Plant Insurance 0.5% of Fc Cost IDR 28,514,094,671 IDR 142,570,473
Employee's Insurance 4% of Salary IDR 6,375,600,000 IDR 255,024,000

Total Insurance IDR 397,594,473
6.2.3. Plant Overhead Cost
Plant overhead cost covers the cost that is needed for safety measures during
production process. The total plant overhead cost is around 50-70% from operating
labour salary. If we assume the total plant overhead about 50%, therefore, the cost for
plant overhead can be calculated as follows.
Plant overhead cost = 50% x IDR 5,013,600,000 = IDR 2,506,800,000
6.2.4. General Expenses
General expense is an expense related to the routine expenses of a plant office
to support the operational activity of the plant. This expense consists of administrative
cost, marketing and distribution cost, annual research and development cost, and
annual financial interest cost for 10 years of life expectancy.
6.2.4.1.Administrative Cost
This calculation is useful for determining the cost of supporting offices in
communicating with outside parties such as suppliers or our retailers.
87
Table 6. 20 Communication Cost

Communication Cost
Component Cost/year (IDR)
Telephone Rp 10,800,000.00
Internet 25 Mbps Unlimited Rp 10,020,000.00
Total Rp 20,820,000.00
6.2.4.2.Marketing Cost
Marketing is conducted on printed media, online media, and direct publication
via booth and exhibition.
Table 6. 21 Marketing Cost
Types Cost / Year (IDR)
Printed Advertisement Cost Rp 71,150,000
Online Media Cost Rp 17,300,000
Exhibition and Project Auction Cost Rp 12,200,000
Total Marketing Cost Rp 100,650,000
6.2.4.3.Product Distribution Cost
Product distribution use two kinds of transportation with total 5 vehicles which
are 2 Mitsubishi Colt Diesel Double (CDD) box with cargo capacity 8 tons, and 3
Tronton box with cargo capacity 15 tons. Those vehicles use solar fuel as its energy.
Table 6. 22 Product Distribution Frequency

Number Distance
Route Pathway Frequency
of Truck (km)
Cilegon-Tangerang- Land Every 1 346
Depok-Bekasi-Cilegon week
(Lane I)
Cilegon-DKI Jakarta- Land Every 3 248
Cilegon (Lane II) week
Cilegon-Bandung- Land Every 2 512
Cilegon (Lane III) week
88
Table 6.22 Product Distribution Frequency (continued)
Number Distance
Route Pathway Frequency
of Truck (km)
Cilegon-Semarang- Land Every 3 1094
Cilegon (Lane IV) week
Cilegon-Palembang- Land & Every 3 1040
Cilegon (Lane V) Water week
Table 6. 23 Product Distribution Cost
Solar
Fuel cost per Toll and Freight Total cost
Route Consumption Total cost per year
week cost per week per week
(L)
Lane I 34.6 Rp 178,190 Rp 224,500 Rp 402,690 Rp 20,134,500
Lane II 24.8 Rp 383,160 Rp 480,000 Rp 863,160 Rp 43,158,000
Lane III 51.2 Rp 527,360 Rp 720,000 Rp 1,247,360 Rp 62,368,000
Lane
109.4 Rp 1,690,230 Rp 1,520,000 Rp 3,210,230 Rp 160,511,500
IV
Lane V 97.2 Rp 1,501,740 Rp 6,931,654 Rp 8,433,394 Rp 421,669,700
Total Rp 707,841,700
6.2.4.4.Loan Interest
Grand Night capital investment cost is obtained from bank and investor. In this
project, the capital investment is assumed to be obtained from bank with the fraction
of 40% and 60% from the investor. The interest rate is shown at table 6.24.
Table 6. 24 Source Proportion of Capital Investment
Capital Source Percentage Capital Share Interest Rate
Bank Central Asia 40% IDR 22,516,208,880 9.75%
Investor 60% IDR 33,774,313,320 10.50%
Total 100% IDR 56,290,522,200
The loan is paid with the assumption of 5 years, with each year paid the same
value of initial loan, loan interest excluded. Total loan payment that will be paid
annually is normal loan payment which has same value every year plus loan interest.
From calculation in Appendices E total payment of interest per year is
89
Table 6. 25 Calculation of Loan Interest from Bank and Investor

Year Interest payment
1 IDR 16,999,737,704
2 IDR 15,851,411,052
3 IDR 14,703,084,399
4 IDR 13,554,757,746
5 IDR 12,406,431,093
6.2.4.5.Research and Development Cost

The research and development cost is less than 0.5% of the total income that
will be earned during the year for small and medium chemical engineering business
administration. However, product such as granite are not really need R&D thus the
multiplier is very small.
𝑑𝑎𝑦𝑠
𝑇𝑜𝑡𝑎𝑙 𝑟𝑒𝑣𝑒𝑛𝑢𝑒 = (400 𝑚2 𝑥300 𝑥 𝐼𝐷𝑅 480.000 2 )
𝑦𝑒𝑎𝑟 𝑚
𝑑𝑎𝑦𝑠
+ (432 𝑚2 𝑥300 𝑥 𝐼𝐷𝑅 350.000 2 ) = 𝐼𝐷𝑅 103.584.000.000
𝑦𝑒𝑎𝑟 𝑚
𝑅𝑛𝐷 𝑐𝑜𝑠𝑡 = 0.0012𝑥𝑇𝑜𝑡𝑎𝑙 𝑟𝑒𝑣𝑒𝑛𝑢𝑒 = 𝐼𝐷𝑅 124.800.000
6.2.5. Summary of Operational Cost
90
Table 6. 26 Summary of Operational Cost

2021 2022 2023 2024 2025
Raw Material (+transportation) IDR 25,501,520,984 IDR 25,501,520,984 IDR 25,501,520,984 IDR 25,501,520,984 IDR 25,501,520,984
DIRECT
Utility IDR 269,279,512 IDR 269,279,512 IDR 269,279,512 IDR 269,279,512 IDR 269,279,512
PRODUCTION
COST Patent IDR 19,150,000 IDR 19,150,000 IDR 19,150,000 IDR 19,150,000 IDR 19,150,000
Labour&Executive Salary IDR 5,013,600,000 IDR 5,013,600,000 IDR 5,013,600,000 IDR 5,013,600,000 IDR 5,013,600,000
Local Tax IDR 6,706,509,000 IDR 6,706,509,000 IDR 6,706,509,000 IDR 6,706,509,000 IDR 6,706,509,000
FIXED COST Insurance IDR 318,223,282 IDR 318,223,282 IDR 318,223,282 IDR 318,223,282 IDR 318,223,282
Plant Overhead IDR 2,506,800,000 IDR 2,506,800,000 IDR 2,506,800,000 IDR 2,506,800,000 IDR 2,506,800,000
Marketing and Communication IDR 121,470,000 IDR 121,470,000 IDR 121,470,000 IDR 121,470,000 IDR 121,470,000
GENERAL Product Distribution IDR 707,841,700 IDR 707,841,700 IDR 707,841,700 IDR 707,841,700 IDR 707,841,700
EXPENSES Research and Development IDR 124,800,000 IDR 124,800,000 IDR 124,800,000 IDR 124,800,000 IDR 124,800,000
Loan Interest IDR 16,999,737,704 IDR 15,851,411,052 IDR 14,703,084,399 IDR 13,554,757,746 IDR 12,406,431,093
TOTAL OPEX (excluding maintenance & depreciation) IDR 41,289,194,478 IDR 41,289,194,478 IDR 41,289,194,478 IDR 41,289,194,478 IDR 41,289,194,478
MAINTENANCE IDR 734,195,915 IDR 734,195,915 IDR 734,195,915 IDR 734,195,915 IDR 734,195,915
DEPRECIATION IDR 648,621,468 IDR 590,427,661 IDR 537,853,185 IDR 490,342,108 IDR 447,393,911
TOTAL ANNUAL EXPENSES IDR 59,671,749,566 IDR 58,465,229,107 IDR 57,264,327,977 IDR 56,068,490,247 IDR 54,877,215,397
91
Table 6. 26 Summary of Operational Cost (continued)
2026 2027 2028 2029 2030

Raw Material (+transportation) IDR 25,501,520,984 IDR 25,501,520,984 IDR 25,501,520,984 IDR 25,501,520,984 IDR 25,501,520,984
DIRECT
Utility IDR 269,279,512 IDR 269,279,512 IDR 269,279,512 IDR 269,279,512 IDR 269,279,512
PRODUCTION
COST Patent IDR 19,150,000 IDR 19,150,000 IDR 19,150,000 IDR 19,150,000 IDR 19,150,000
Labour&Executive Salary IDR 5,013,600,000 IDR 5,013,600,000 IDR 5,013,600,000 IDR 5,013,600,000 IDR 5,013,600,000
Local Tax IDR 6,706,509,000 IDR 6,706,509,000 IDR 6,706,509,000 IDR 6,706,509,000 IDR 6,706,509,000
FIXED COST Insurance IDR 318,223,282 IDR 318,223,282 IDR 318,223,282 IDR 318,223,282 IDR 318,223,282
Plant Overhead IDR 2,506,800,000 IDR 2,506,800,000 IDR 2,506,800,000 IDR 2,506,800,000 IDR 2,506,800,000
Marketing and Communication IDR 121,470,000 IDR 121,470,000 IDR 121,470,000 IDR 121,470,000 IDR 121,470,000
GENERAL Product Distribution IDR 707,841,700 IDR 707,841,700 IDR 707,841,700 IDR 707,841,700 IDR 707,841,700
EXPENSES Research and Development IDR 124,800,000 IDR 124,800,000 IDR 124,800,000 IDR 124,800,000 IDR 124,800,000
Loan Interest IDR 0 IDR 0 IDR 0 IDR 0 IDR 0
TOTAL OPEX (excluding maintenance & depreciation) IDR 41,289,194,478 IDR 41,289,194,478 IDR 41,289,194,478 IDR 41,289,194,478 IDR 41,289,194,478
MAINTENANCE IDR 734,195,915 IDR 734,195,915 IDR 734,195,915 IDR 734,195,915 IDR 734,195,915
DEPRECIATION IDR 408,557,953 IDR 373,428,488 IDR 341,640,180 IDR 312,864,066 IDR 286,803,927
TOTAL ANNUAL EXPENSES IDR 42,431,948,347 IDR 42,396,818,882 IDR 42,365,030,574 IDR 42,336,254,460 IDR 42,310,194,321
92
6.3 Depreciation
Depreciation is basically the reduction of assets value which is calculated
after the assets are purchased. The capital investment in the beginning of the project
will lose its fraction of value into salvage value at the end of the project. In each
annuity, the depreciation needs to be calculated to provide a balance from the initial
capital investment to the final salvage value.
For the further calculation, we will use declining –balance method. The
depreciation rate for equipment is estimated to be 10% per year, and depreciation
rate for building is estimated to be 3% per year. Through the conducted calculation
of depreciation, the total depreciation per year can be tabulated as follow.
Table 6. 27 Total Depreciation Calculation

TOTAL DEPRECIATION
Year Total Depreciation
2021 Rp 648,621,468.27
2022 Rp 590,427,661.44
2023 Rp 537,853,185.10
2024 Rp 490,342,107.69
2025 Rp 447,393,910.80
2026 Rp 408,557,953.17
2027 Rp 373,428,488.31
2028 Rp 341,640,180.02
2029 Rp 312,864,066.34
2030 Rp 286,803,926.90
Total Depreciation Rp 4,437,932,948.02
The depreciation gives salvage value of main equipment, building, and
supporting equipment as shown below. This value of salvage value will act as the
inflow in cashflow at the end of the project.
Total Salvage Value in 2030 = IDR 13,871,061,734.64
6.4 Cost Breakdown

For the basic of sensitivity analysis, it is important to know which expense
shares the most to produce one unit of product. The share percentage is calculated
93
on the basis of annual cost. Since capital investment comes only in year 2020 and
2030 as salvage value, the amount of capital investment annually needs to be
calculated by a factor of A/P for capital investment and A/F for salvage value. The
calculation process is tabulated below.
Table 6. 28 Calculation of Cost Breakdown
Average Annual Share
Component Share
Cost Percentage (%)
Capital Investment IDR 17,884,013,981 26.59 IDR 93,064 IDR 127,631
Raw Material IDR 25,501,520,984 37.92 IDR 132,704 IDR 181,994
Labour & Executive Salary IDR 5,013,600,000 7.45 IDR 26,090 IDR 35,780
Utility IDR 269,279,512 0.40 IDR 1,401 IDR 1,922
Maintenance IDR 734,195,915 1.09 IDR 3,821 IDR 5,240
Patent & Royalty IDR 19,150,000 0.03 IDR 100 IDR 137
Local Tax IDR 6,706,509,000 9.97 IDR 34,899 IDR 47,862
Insurance IDR 318,223,282 0.47 IDR 1,656 IDR 2,271
Plant Overhead IDR 2,506,800,000 3.73 IDR 13,045 IDR 17,890
Marketing and
IDR 121,470,000 0.18 IDR 632 IDR 867
Communication
Distribution IDR 707,841,700 1.05 IDR 3,683 IDR 5,052
Loan Interest IDR 7,351,542,199 10.93 IDR 38,256 IDR 52,465
Research and Development IDR 124,800,000 0.19 IDR 649 IDR 891
IDR 67,258,946,574 100.00 IDR 350,000 IDR 480,000
Figure 6. B Cost Breakdown of Grand Night Ceramic Floor
94
From the cost estimation, it can be inferred that the major expenses to
produce a unit of ceramic floor comes from raw material. The next aspect with large
amount of share is labor and executive salary also loan interest and capital
investment. These expense items will be analyzed in sensitivity analysis in the next
section.
6.5 Product Price
One way to determine product price is by determining the minimum product
price beforehand. The minimum product price is obtained when NPV = 0. The
method of Goal Seek provides the result that when NPV = 0, the minimum product
price for size 60x60 is IDR 259,873 / m2 and for size 100x100 is IDR 130,000
higher than size 60x60 which brings the cost to IDR 389,873 / m2. Profit margin
taken and the adjusted product price are shown in Table 6.30 and 6.31
Table 6. 29 Product Price Calculation for size 60x60
Component Value
Minimum Price (IDR) IDR 259,873
Yearly Production Capacity (m2) IDR 249,600
Profit Margin (%) 30%
Product Price (IDR) IDR 337,835
Adjusted Product Price (IDR) IDR 350,000
Adjusted Product Margin (%) 34.68%
Table 6. 30 Product Price Calculation for size 100x100

Component Value
Minimum Price (IDR) IDR 389,873
Yearly Production Capacity (m2) IDR 249,600
Profit Margin (%) 20%
Product Price (IDR) IDR 467,848
Adjusted Product Price (IDR) IDR 480,000
Adjusted Product Margin (%) 23.12%
6.6 WACC and MARR
WACC is the measure of minimum return of capital investment that must
be paid by the company to the investor, bank, or another capital investment
provider. In profitability analysis, Minimum Attractive Rate of Return (MARR) is
95
calculated as the same value as WACC. To calculate WACC, the formula used is
stated as follow.
𝐸 𝐷
𝑊𝐴𝐶𝐶 = 𝑅𝑒 + 𝑅
𝐸+𝐷 𝐸+𝐷 𝑑
Re = Riskfree Rate – β(market return – risk free rate)

Rd = Bank interest rate (1-tax rate)
With
𝐸
= 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑒𝑞𝑢𝑖𝑡𝑦 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 𝑐𝑜𝑚𝑖𝑛𝑔 𝑓𝑟𝑜𝑚 𝑖𝑛𝑣𝑒𝑠𝑡𝑜𝑟
𝐸+𝐷
𝐷
= 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑑𝑒𝑏𝑡 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 𝑐𝑜𝑚𝑖𝑛𝑔 𝑓𝑟𝑜𝑚 𝑙𝑜𝑎𝑛
𝐸+𝐷
𝑅𝑒 = 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑒𝑞𝑢𝑖𝑡𝑦
𝑅𝑑 = 𝑐𝑜𝑠𝑡 𝑜𝑓 𝑑𝑒𝑏𝑡
For calculation, risk of free rate and market return is obtained from data of
market risk premia for Indonesia up to March 2018, with risk-free rate equals 7.67%
and market return return equals 10.21%. Beta equity is taken with for pet product
as the closest estimate to the product category with the value of 1.01. The
calculation process gives WACC value to 9.07% as can be seen on the table below.
Table 6. 31 Calculation of WACC
Item Value
Risk-free Rate 7.67%
Beta Equity 1.01
Equity Market Return 10.21%
Cost of Equity 10.24%
Rate of Equity 60%
Bank Interest Rate 9.75%
Tax Rate 25%
Debt
Cost of Debt 7.31%
Rate of Debt 40%
WACC (%) 9.07%
96
6.7 Cash Flow

Cash flow is the amount of cash coming out and coming in as a result of
company activities, in other words consisting of company inflows and cash
outflows of companies and their balances for each period. In making cash flow, the
components used are as follows:
1. Year
2. Product sold and individual price
3. Revenue (Total income)
4. OPEX (Operation Expenses)
5. Maintenance cost
6. Depreciation
7. Loan Interest (can be included in OPEX)
8. Cash expenses (OPEX + Maintenance cost + Loan Interest)
9. All expenses (Cash expenses + Depreciation)
10. Gross profit/Before Tax Cash Flow (Revenue - Cash expenses)
11. Taxable Income or Net Profit Before Tax (BTCF – Depreciation)
12. Income Tax (Taxable Income x Tax Rate)
13. Net Profit After Tax or After Tax Cash Flow (BTCF – Income Tax)
14. Cumulative Cash Flow
There are two segments in cash flow that are used after tax cash flow and
before tax cash flow. Cash inflows come from product sales, and cash outflows
come from capital and operating costs. Income tax is calculated by including
depreciation as a deduction from income tax. Income tax rate is assumed to be 25%
according to normal rate of Indonesia corporate income tax for companies with a
gross turnover above IDR 50 billion.
The product actual price is higher than its minimum price, determined to be
IDR 350,000 per unit for size 60x60 and IDR 480,000 for size 100x100 which
generates progressive income per year. Because this product is an exclusive product
and is not yet available in the market so that for initial production until 2030 it is
assumed that 60% of the sold product is determined with a 5-10% increase in each
year, until it get stable to 90% sold product from 2025. This cash flow is useful for
97
profitability and sensitivity analysis in the next section. The cashflow calculation is
shown in Appendices F
Cash Flow
IDR 60,000,000,000
IDR 40,000,000,000
IDR 20,000,000,000
IDR
IDR 0 Before Tax Cash Flow

0 1 2 3 4 5 6 7 8 9 10 After Tax Cash Flow
-IDR 20,000,000,000
-IDR 40,000,000,000
-IDR 60,000,000,000
Year
Figure 6. C Cash Flow of 10 Years Lifetime Grand Night Product
98
CHAPTER VII
PROFITABILITY AND SENSITVITY ANALYSIS
7.1.Rate of Return
Return of Investment (ROI) is the annual interest rate made by the profits
on the original investment. ROI depicts the plant’s profitability by using the
estimation of the elements of the investment and the pre-tax or after-tax earnings.
To calculate ROI, the benefit (or return) of an investment is divided by the cost of
the investment. The result is expressed as a percentage or a ratio. The most common
ROI equation is defined as:
annual net profit
ROI = x 100%
total capital investment
The criterion to determine whether the business is viable or not is by comparing the
ROI with the MARR set. If the ROI is bigger or equal than MARR then the business
is viable and vice versa. ROI is the benefit to an investor resulting from an
investment of some resource. A high ROI means the investment gains compare
favorably to investment cost. The amount of annual net profit is Rp 12,196,095,814
while the amount of total capital investment is Rp 56,290,522,200. The value of
ROI can be calculate using net profit of the third year:
IDR 12,196,095,814
𝑅𝑂𝐼 = 𝑥100% = 21%
IDR 56,290,522,200
Based on the amount of ROI (21%) it can be seen that Grand Night
production is an interesting investment for investor because it can be said that the
project is likely to be implemented and profitable. The bigger ROI value, the more
money that turn into profit from plant investment. We set our MARR at 12%. This
means that our product is very viable and profitable.
7.2. Payback Period
Payback period refers to the period of time required to recoup the funds
expended in an investment, or to reach the break-even point, or the length time
required to recover the cost of investment. Typically, the pre-determined period of
payback period in the project is less than six years. If the payback period is less than
a pre-determined period, the project is acceptable. If the payback period exceeds
99
the predetermined period, the project is rejected. The payback period ignores the
time value of money, unlike other methods of capital budgeting, such as net present
value, internal rate of return or discounted cash flow, but it’s easy to understand.
Calculation of the cumulative present value from year one on to year two and so on
until year ten. Longer payback periods are not typically desirable for investment
positions. Based on assumptions, the formula to calculate the payback period of
investment cost’s recovery and the calculation are down below.
𝑃𝐵𝑃 − 𝑌𝑒𝑎𝑟 𝑎𝑡 𝑡ℎ𝑒 ℎ𝑖𝑔ℎ𝑒𝑠𝑡 𝑛𝑒𝑔𝑎𝑡𝑖𝑣𝑒 𝑜𝑓 𝐶𝐴𝑇𝐶𝐹
𝑌𝑒𝑎𝑟 𝑎𝑡 𝑡ℎ𝑒 𝑙𝑜𝑤𝑒𝑠𝑡 𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒 𝑜𝑓 𝐶𝐶𝐹 − 𝑌𝑒𝑎𝑟 𝑎𝑡 𝑡ℎ𝑒 ℎ𝑖𝑔ℎ𝑒𝑠𝑡 𝑛𝑒𝑔𝑎𝑡𝑖𝑣𝑒 𝑜𝑓 𝐶𝐴𝑇𝐶𝐹
0 − 𝐻𝑖𝑔ℎ𝑒𝑠𝑡 𝑛𝑒𝑔𝑎𝑡𝑖𝑣𝑒 𝑜𝑓 𝐶𝐴𝑇𝐶𝐹
=
𝐿𝑜𝑤𝑒𝑠𝑡 𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒 𝑜𝑓 𝐶𝐶𝐹 − ℎ𝑖𝑔ℎ𝑒𝑠𝑡 𝑛𝑒𝑔𝑎𝑡𝑖𝑣𝑒 𝑜𝑓 𝐶𝐴𝑇𝐶𝐹
Table 7. 1 Payback Period Calculation

Year Cash Flow (IDR) Cumulative Cash Flow (IDR)
0 -Rp56,290,522,200 -Rp56,290,522,200
1 Rp2,226,809,293 -Rp54,063,712,907
2 Rp6,934,505,831 -Rp47,129,207,075
3 Rp11,643,607,202 -Rp35,485,599,873
4 Rp20,214,974,422 -Rp15,270,625,451
Table 7.1 Payback Period Calculation (Continued)

Year Cash Flow (IDR) Cumulative Cash Flow (IDR)
5 Rp28,787,482,363 Rp13,516,856,912
6 Rp38,082,596,693 Rp51,599,453,605
7 Rp38,073,814,327 Rp89,673,267,931
8 Rp38,065,867,250 Rp127,739,135,181
9 Rp38,058,673,221 Rp165,797,808,402
10 Rp38,052,158,186 Rp203,849,966,589
Based on calculation of interpolation in Microsoft Excel, the Payback

Period of Grand Night is 4.53 years or equals to 1631 days. We can conclude that
Grand Night Self-Healing Ceramics Floor can be run, because it has payback period
less than 6 years, so it is acceptable. There are several advantages and disadvantages
using payback period method to determine the feasibility of a company.
The disadvantages are:
1. Ignores the time value of money.
2. Ignores cash flows after the payback period.
100
3. Biased against long-term projects.

4. Requires arbitrary acceptance criteria.
5. A project accepted based on the payback criteria may not have a positive
NPV.
The advantages are:
1. Easy to understand.
2. Biased toward liquidity.
The graph of the payback period can be seen below.
Payback Period
2.5E+11
2E+11
1.5E+11
1E+11
5E+10
0
0 1 2 3 4 5 6 7 8 9 10
-5E+10
-1E+11
Figure 7. 1 Cummulative Cash Flow vs. Year for Payback Period Calculation
From the figure above, we can conclude that our product payback period is in
the five year of production.
7.3. Break Even Point
Breakeven point (BEP) is an analysis which is done to define and determine
the amount of goods or services that must be sold to the consumer with a determined
price to cover the costs that emerge and obtain profit. Based on the calculation, the
payback period of the plant is 4.53 years or approximately 1631 days of work.
Therefore the amount of production until 1656 days can be used to determine the
BEP. BEP can be achieved with this formula below.
𝐹𝑖𝑥𝑒𝑑 𝐶𝑜𝑠𝑡
𝐵𝐸𝑃 =
𝑃𝑟𝑖𝑐𝑒 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 − 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝐶𝑜𝑠𝑡 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡
𝐵𝐸𝑃→𝑇𝐶=𝑇𝑅
TC is total cost and TR is total revenue. BEP is a point where the annual
profit can cover the fixed cost. To calculate breakeven point in sales volume, the
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values of three variables should be identified. Those three variables are fixed costs,
variable costs, the price of the product. Fixed cost is a kind of cost that always fixed
and not influenced by the selling volume, but influenced with time, so that this kind
of cost will be constant during certain period. Variable cost is a kind of cost that
always changes along with the change of selling volume, where the change reflected
in total variable cost. The price of the product has been set by the company through
looking at the wholesale cost of the product or the cost of manufacturing the product
and marking it up.
Table 7. 2 Breakeven Point Calculation based on Payback Period

Sold Product Sold Product Cumulative of
Years Products
(%) (unit) Sold Product
1 249600 0.6 149760 149760

2 249600 0.65 162240 312000
3 249600 0.7 174720 486720
4 249600 0.8 199680 686400
4.5305 132403 0.9 119163 805563
7.4. Internal Rate of Return
Internal rate of return (IRR) is a metric used in capital budgeting to estimate
the profitability of potential investments and the maximum interest rate paid on a
project that can still be breakeven at the end of the project life. Internal rate of return
is a discount rate that makes the net present value (NPV) of all cash flows (both
positive and negative) from a particular project equal to zero. Internal rate of return
is used to evaluate the attractiveness of a project or investment. IRR calculations
rely on the same formula as NPV does. Equation below can be used to calculate the
value of IRR.
n =T
CFn
NPV =  − TCI = 0
n =1 (1 + r )n
where r is the value of IRR while TCI is the total capital investment. The calculation
of IRR is done by the aid of Microsoft Excel software (it already had a function to
calculate IRR for economic analysis). Based on the calculation in Ms. Excel, the
obtained IRR is 27.671%.
102
A project can be determined as a feasible project if the IRR value is greater

than MARR value. From the previous chapter, the value of MARR is 12%, which
is the usual amount of MARR for home building. IRR value is greater than MARR
value (27.671% > 12%). Therefore, we can also conclude that Grand Night plant is
a feasible and acceptable project because it can give profit for the investor.
7.5. Net Present Value

Net Present Value (NPV) is a value that shows the net benefits received by a
project over the life of the project at a certain interest rate. NPV is used in capital
budgeting to analyze the profitability of a projected investment or project. During
the calculation of NPV, we must also determine the relevant interest rate. In
calculating the NPV is necessary to determine the relevant interest rate. For this
calculation, we also used the MARR value that has been calculated before, which
12%. Net present value can be calculated by Equation below.
CFn
CFn , 0 =
(1 + i )n
where :
• CFn = The net cash flow in time- n
• i = Interest rate used in the project
• n = Time of the project
𝑃
𝑁𝑒𝑡 𝑝𝑟𝑒𝑠𝑒𝑛𝑡 𝑤𝑜𝑟𝑡ℎ (𝑁𝑃𝑉) = 𝑡ℎ𝑒 𝑠𝑢𝑚 𝑜𝑓 (𝐴𝑇𝐶𝐹 𝑥 𝑣𝑎𝑙𝑢𝑒)
𝐹
If NPV is greater than zero, it means that the project is profitable or could
give benefits if it’s executed while if the NPV is less than zero it means that project
is not profitable to run. If NPV value equals to zero, it means that the project won’t
result in any profit or loss. From the calculation with Ms. Excel application, we
obtained the NPV value of IDR 81,852,992,042. Because the NPV value is greater
than zero, based on NPV calculation we can conclude that this project is profitable
and feasible to be established.
7.6. Sensitivity Analysis
Sensitivity analysis is an analysis that examines the effect of the instability
of the components that affect the plant profit as selling prices of product, operating
costs, cost of raw material, and others against the parameters of profitability. The
103
purpose of this sensitivity analysis is for looking at the feasibility of a project.

Profitability parameter that is used in this analysis is NPV, IRR, and payback
period.
7.6.1. Selling Price Fluctuations
This type of sensitivity analysis was performed based on the fluctuation of
product sales price that is decrease and increase. The selling price of products is
one of the important variables that can affect the stability of production because
these variables will determine the revenue and profit to be earned by the industry.
The parameter which is observed in this calculation is the change in economic
viability parameter such as NPV, IRR, and PBP if there is a decline in the level of
product sales. The calculation of this analysis is shown in the table below.
Table 7. 3 Selling Price Fluctuations for 60x60 cm Ceramics Floor
Product Price
Change (%) IRR (%) NPV (Rp) PBP (years)
(Rp)
-20% IDR 280.000 20,59% IDR 49.653.297.711 5,5362
-15% IDR 297.500 22,41% IDR 57.813.780.971 5,2316
-10% IDR 315.000 24,28% IDR 65.974.264.230 4,9633
Table 7.3 Selling Price Fluctuations for 60x60 cm Ceramics Floor (Continued)
Product Price
Change (%) IRR (%) NPV (Rp) PBP (years)
(Rp)
-5% IDR 332.500 25,98% IDR 73.978.500.613 4,7319
0% IDR 350.000 27,67% IDR 81.852.992.042 4,5305
5% IDR 367.500 29,35% IDR 89.727.483.472 4,3494
10% IDR 385.000 31,03% IDR 97.601.974.902 4,1857
15% IDR 402.500 32,69% IDR 105.476.466.331 4,0371
20% IDR 420.000 34,35% IDR 113.350.957.761 3,9015
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Table 7. 4 Selling Price Fluctuations for 100x100 cm Ceramics Floor

Product Price
Change (%) (Rp) IRR (%) NPV (Rp) PBP (years)
-20% IDR 384.000 18,60% IDR 40.845.157.050 5,9148
-15% IDR 408.000 20,93% IDR 51.207.675.475 5,4751
-10% IDR 432.000 23,25% IDR 61.570.193.900 5,1040
-5% IDR 456.000 25,52% IDR 71.853.637.846 4,7902
0% IDR 480.000 27,03% IDR 87.814.204.000 4,5998
5% IDR 504.000 29,81% IDR 91.852.346.239 4,3036
10% IDR 528.000 31,92% IDR 101.851.700.435 4,1038
15% IDR 552.000 34,03% IDR 111.851.054.631 3,9264
20% IDR 576.000 36,13% IDR 121.850.408.828 3,7678
From the table above, if the deviation decreases then NPV will decrease, and
if the deviation increases then NPV will increase. Same with NPV, when deviation
decreases then IRR will decrease. However, if the deviation decreases then payback
period will increase. It means the cheaper the price of our products then the longer
payback period we can get.
From this analysis, it can be deduced that the price should be higher to achieve
a more feasible project. However, the factor of competitiveness with the existing
products should be taken into account. Hence, the product price of IDR 350,000 for
60x60 cm and IDR 480,000 for 100x100 cm ceramics floor are taken as the
optimum standard, which provide economic feasibility yet still acceptable in the
market.
7.6.2. Raw Material Cost Changes
In this part, sensitivity analysis was conducted by a decrease and increase
in raw material prices. The cost of raw materials may fluctuate, considering the
price of raw materials is determined by suppliers and distribution of raw materials
also tend to change due to changes in fuel, and other aspects. The calculation of
economic feasibility parameters to changes in raw material prices is in the table
below.
105
Table 7. 5 Raw Material Cost Fluctuations

PBP
Change Raw Material Cost (Rp) IRR (%) NPV (Rp)
(years)
-20% IDR 20,401,216,787 36.66% IDR 112,577,430,909 3.7225
-15% IDR 21,676,292,836 34.26% IDR 104,896,321,192 3.9026
-10% IDR 22,951,368,886 31.97% IDR 97,215,211,476 4.0962
-5% IDR 24,226,444,935 29.78% IDR 89,534,101,759 4.3049
0% IDR 25,501,520,984 27.67% IDR 81.852.992.042 4.5305
5% IDR 26,776,597,033 25.65% IDR 74,171,882,326 4.7751
10% IDR 28,051,673,082 23.61% IDR 66,235,202,593 5.0529
15% IDR 29,326,749,132 21.63% IDR 58,205,188,515 5.3606
From the table above, if the cost increase, NPV value tends to be smaller,
while if the cost decrease, otherwise will happen. Along with NPV, IRR will also
decrease by the change or increase in cost. A longer payback period will also be
obtained if the cost that influences production process increase.
As of now, the share of product cost is dominated by the raw material, as it
is expensive and quite difficult to get. Because of it, raw material influences the
profitability parameter quite significantly compared to other expenses. Hence, the
ways to cut off the raw material cost must be explored.
7.6.3. Operational Cost Changes
This sensitivity analysis was performed on the change of the operational
costs of the product. Changes in the variable labor costs are one of the variables that
affect the cost of production in the factory so that it can be used to analyze the
stability of the project. NPV value will be smaller by the increase of operational
costs. The change in operational cost will also cause the change in IRR value.
Increasing labor cost or operating cost will decrease the value of IRR. Lower IRR
value means that the return will be smaller (become less profitable). Aside from
NPV and IRR, PBP value will also change as the result of change in labor cost. PBP
tends to be longer if the labor cost increases. The calculation of operational labor
costs fluctuation is shown in the table below.
106
Table 7. 6 Operating Cost Fluctuation

PBP
Change Labor Salary (Rp) IRR (%) NPV (Rp)
(years)
-20% IDR 4,010,880,000 29.90% IDR 90,341,169,151 4.2904
-15% IDR 4,261,560,000 29.33% IDR 88,219,124,874 4.3484
-10% IDR 4,512,240,000 28.78% IDR 86,097,080,596 4.4077
-5% IDR 4,762,920,000 28.22% IDR 83,975,036,319 4.4684
0% IDR 5,013,600,000 27.67% IDR 81,852,992,042 4.5305
5% IDR 5,264,280,000 27.13% IDR 79,730,947,765 4.5940
10% IDR 5,514,960,000 26.59% IDR 77,608,903,488 4.6590
15% IDR 5,765,640,000 26.05% IDR 75,486,859,211 4.7256
20% IDR 6,016,320,000 25.52% IDR 73,364,814,934 4.7938
From the sensitivity analysis, the change of labor salary does not influence
the profitability parameter in a significant way. Hence, the way to control labor
salary to get more profit is not the main concern in this project.
7.6.4. Loan Interest Changes
This sensitivity analysis was performed on the change of the loan interest of
the capital investment. Capital investment refers to money used by a business to
purchase fixed assets, such as land, machinery, or buildings which will be
purchased once in the beginning of the company. Capital investment can be gained
either through investors or investment banks. Changes in the loan interest is one of
the variables that affect the capital investment in the factory so that it can be used
to analyze the stability of the project. The observed parameter in this analysis is
also the change in economic viability parameter (NPV, PBP, and IRR). The
calculation of loan interest fluctuation is shown in the table below.
Table 7. 7 Loan interest fluctuation

PBP
Change (%) Product Price (Rp) IRR (%) NPV (Rp)
(years)
-20% IDR 58.812.337.594 30,10% IDR 89.810.972.759 4,1992
-15% IDR 62.488.108.694 29,48% IDR 87.821.477.580 4,2782
-10% IDR 66.163.879.794 28,87% IDR 85.831.982.401 4,3596
-5% IDR 69.839.650.893 28,27% IDR 83.842.487.222 4,4437
0% IDR 73.515.421.993 27,67% IDR 81.852.992.042 4,5305
5% IDR 77.191.193.093 27,09% IDR 79.863.496.863 4,6201
10% IDR 80.866.964.192 26,51% IDR 77.874.001.684 4,7127
15% IDR 84.542.735.292 25,90% IDR 75.790.834.046 4,8125
20% IDR 88.218.506.392 25,28% IDR 73.622.701.812 4,9196
107
7.6.5. Fluctuation Graphics

The sensitivity analysis conducted is then represented by the graphic
mapping each component with each profitability parameter.
• Net Present Value
IDR 120,000,000,000
Product Price
IDR 100,000,000,000
IDR 80,000,000,000 Raw Material

NPV (IDR)
IDR 60,000,000,000
Labor Salary
IDR 40,000,000,000
IDR 20,000,000,000 Loan Interest

IDR 0
-30% -20% -10% 0% 10% 20% 30% Linear (Product
Price)
CHANGE (%)
Figure 7. 2 Net Present Value Fluctuation (60x60cm product size)

IDR 140,000,000,000
IDR 120,000,000,000
Product Price
IDR 100,000,000,000
Raw Material
NPV (IDR)
IDR 80,000,000,000
Labor Salary
IDR 60,000,000,000
Loan Interest
IDR 40,000,000,000
Linear (Product Price)
IDR 20,000,000,000 Linear (Raw Material)
IDR 0 Linear (Labor Salary)
-30% -20% -10% 0% 10% 20% 30%
CHANGE (%)
Figure 7. 3 Net Present Value Fluctuation (100x100cm product size)
From graphic above, it can be seen that the influence of labor cost is not
significant but it causes changes in NPV. Raw materials and product price cost
caused NPV changed significantly. The increasing of product cost causes the
increase of NPV, whereas the increase of raw materials cost causes a decline of
NPV.
• Internal Rate of Return
108
40.00%
35.00%
30.00%
Product Price
25.00% Raw Material
IRR (%)
20.00% Labor Salary
15.00% Loan Interest

10.00%
Linear (Raw Material)
5.00%
Linear (Labor Salary)
0.00%
-30% -20% -10% 0% 10% 20% 30%
CHANGE (%)
Figure 7. 4 Internal Rate of Return Fluctuation (60x60cm product size)
40.00%
35.00%
Product Price
30.00%
Raw Material
25.00%
IRR (%)
Labor Salary
20.00%
Loan Interest
15.00%
10.00%
Linear (Raw Material)
5.00%
0.00%
-30% -20% -10% 0% 10% 20% 30%
CHANGE (%)
Figure 7. 5 Internal Rate of Return Fluctuation (100x100cm product size)
From Figure 3.5, it can be seen that the influence of operating labors is not
significant but it causes changes in IRR. The increase of product price causes a
higher value of IRR while the increase of raw materials cost causes decreasing of
IRR.
• Payback Period (PBP)
109
5
Product Price
PBP (years) 4
Raw Material
3 Labor Salary
Loan Interest
2
1 Linear (Raw Material)
0
-30% -20% -10% 0% 10% 20% 30%
CHANGE (%)
Figure 7. 6 Payback Period Fluctuation (60x60cm product size)

7
5 Product Price
PBP (years)
Raw Material
4
Labor Salary
3
Loan Interest
2 Linear (Product Price)
1 Linear (Raw Material)

0
-30% -20% -10% 0% 10% 20% 30%
CHANGE (%)
Figure 7. 7 Payback Period Fluctuation (100x100cm product size)

From Figure 7.7, it can be seen that the influence of labor cost is not that
significant but it causes changes in PBP. The product price causes the highest
fluctuation at value about 4-5 years change of payback period. The increasing of
raw material cost causes a rise of PBP while an increase of product price results in
a decline of PBP. To summarize, the aspect of raw material and product price must
be taken into account to get a more profitable project, as the sensitivity to the
profitability parameter is high. One way that might be done is thorough research to
find alternative raw materials which provides lower cost. Other way to do is by
increasing product price after a period of product existence in the market, when the
product is highly competitive enough with the existing products.
110
CONCLUSIONS
Based on the whole product design from needs to economic analysis, some
important conclusions are listed as follow.
1. The roles of dog shampoo are removing dirt, preventing bacteria, fungus,
and fleas. However, current products usually do not provide all those roles.
2. There are 27 needs interpreted from interviews. The most desirable needs is
anti-scratch ceramics floor.
3. Predictive specification is obtained through metrics preparation,
benchmarking with five existing products, and setting marginal and ideal
value are conducted to get good predictive specification value.
4. Concept generation is proceeded by observing existing concepts and
brainstorming new concepts. First selection by RVF method obtainin 33
remaining concepts from initial 60 concepts.
5. Concept screening as a comparative selection produces 6 concepts. Concept
scoring based on detailed criteria of ease of use, self-healing scratch, self-
healing crack, manufacture process, ingredient availabililty, safety,
durability, aesthetic, toughness, and price.
6. The final concept is “homogeneous structure ceramic with firing process for
healing scratch by polyurethane heat treatment”.
7. The granite product will have the ability to heal scratch with mechanism
from cross-linking bond in polyurethane coating. The homogeneous
structure makes it stronger and not easily cracked. The application of epoxy
resin under the polyurethane layer also makes the floor more flawless.
8. The ingredients needed to make this self-healing ceramics floor are granite
rocks, epoxy resin, dimethylbenzene, butyl acetate, cyclohexanone, 1,4-
butanediol (BDO), dibutylin dilaurate (DBTDL), toluene diisocynate,
polyether polyol HSH220, polyether polyol HSH330, and cardboard box for
packaging.
9. The product is has two size, 60x60 cm2 and 100x100 cm2 and approximately
weight 7 kg/pcs for size 60x60 cm2.
111
10. The product name is “Grand Night”, which represent the elegance of the
product and the glossy look of Grand Night floor pattern, and expected to
be able to work well and effectively with self-healing ability to solve the
main problem of ceramics floor like microcracks, scratch, etc. The tagline
of this product is “Technologies Right Under Your Feet”.
11. The product is expected to be in market by 2021. Production capacity is
obtained from market share which brings the production capacity to 832 m2
granite per day.
12. The ceramics floor production process in carried out in batch mode of
operation with processes broken down from granite blocks to granite slabs,
polishing, cut the granite slab according to the desired size, applying resin,
applying polyuethane, and packaging.
13. On the daily basis, the overall ingredients input is 76.9 kg which gives
overall product output 73 kg. Energy consumed per day is 66.65 kWh per
day. They give the productivity measure of 0.95 kg product/kg ingredient
and energy utilization of 24 kWh/pcs.
14. The plant will be located in Cilegon industrial area which is near Merak Port
so the delivery of raw materials and production can be done easily and the
cost can be cheaper, and the plant will be operated 24 hours with 3 shifts of
workers.
15. Active ingredients are many imported from China with the consideration of
cheaper price and availability in high purity. Daily production capacity of
1600 pieces (832 m2) need 92.4 cbm granite of raw materials, which are
supplied and inventoried in a fixed scheduling order.
16. Total capital investment is estimated to be IDR 57,274,564,656. Annual
operational cost is estimated to be IDR 41,293,540,500.
17. Minimum product price isIDR 258,186 / m2 for granite size 60x60 cm2 and
IDR 388,186 / m2 for granite size 100x100 cm2. By taking profit margin of
35-50%, product price is IDR 350,000/m2 for granite size 60x60 cm2 and
IDR 480,000 / m2 for granite size 100x100 cm2.
18. Through cost breakdown, expenses with major shares are raw material cost
(37.62%) and capital investment (26.85%).
112
19. Profitability analysis deducts that the project is economically feasible with
a. ROI : 20%
b. Payback period : 4.6 years
c. Breakeven point : 821,144 m2
d. IRR : 27%
e. NPV : IDR 87,814,204,000
20. Sensitivity analysis is made with change of product price, raw material
price, labor salary, and loan interest. The most sensitive component is
product price.
113
Deskripsi
5 PROSES PEMBUATAN KERAMIK DENGAN PROTEKSI SELF-HEALING

POLYURETHANE
Bidang Teknik Invensi

Invensi ini berhubungan dengan pembuatan keramik untuk
10 peningkatan faktor keberlanjutan penggunaan, khususnya
untuk pengguna yang ingin membangun bangunan dengan tingkat
pengunjung tinggi.
Latar Belakang Invensi

15 Keramik merupakan salah satu industri yang sangat
cepat dalam pertumbuhannya. Pertumbuhan pembangunan yang
semakin meningkat dan maraknya bisnis properti yang cukup
mendominasi pasar lokal dan dunia serta pergeseran selera
dan kebutuhan masyarakat akan kebutuhan barang-barang mewah
20 merupakan faktor utama yang mendominasi akselerasi dari
industri keramik. Keramik yang mudah retak dan mudah pecah
merupakan salah satu masalah yang sering dialami di rumah,
gedung, perkantoran bahkan di tempat fasilitas umum.
Masalah ini dapat diatasi pada umumnya yaitu dengan
25 menggantinya dengan yang baru. Namun biasanya ada beberapa
kendala yang terjadi seperti sulit dalam pemasangannya,
membutuhkan alat khusus untuk membuatnya menjadi tetap
rapih dan terlihat bagus sehingga ini menjadi permasalahan
tersendiri. Ada beberapa alternatif selain dengan
30 menggantinya yaitu menggunakan keramik dengan kemampuan
khusus, salah satunya yaitu dengan kemampuan anti gores.
Keramik ini dapat digunakan di dalam ruangan dalam jangka
waktu yang lama.
114
Keramik pada umumnya memiliki tekstur yang keras dan
memiliki corak yang sangat bervariatif. Namun keramik yang
ada dipasaran saat ini memiliki kelemahan yaitu tidak tahan
gores. Keramik yang tahan gores sangatlah penting karena
5 apabila terjadi goresan kecil pada keramik secara terus
menerus maka seiring berjalannya waktu akan menimbulkan
keretakan pada keramik sehingga mudah retak dan pecah.
Keramik yang sudah ada saat ini dibuat melalui proses
pembakaran pada suhu tinggi sehingga menghasilkan tekstur
10 keramik yang keras dan memiliki corak yang sangat
bervariatif. Produk keramik yang sudah jadi harus memenuhi
standar pembuatan keramik yang berlaku di Indonesia
sehingga keramik memiliki kualitas yang baik dan siap untuk
digunakan. Invensi yang diajukan oleh inventor adalah
15 penambahan polyurethane pada pembuatan keramik yang belum
pernah digunakan sebelumnya sebagai material anti gores
pada keramik.
Ringkasan Invensi
20 Invensi yang diajukan ini pada prinsipnya adalah
membuat produk lantai keramik anti gores yang tahan lama,
ekonomis, aman, dan berkualitas. Pada akhirnya produk ini
akan ketertarikan masyarakat untuk menggunakan lantai
keramik yang anti gores karena keunggulan yang ditawarkan
25 seperti tahan lama, desain yang bervariasi, kemudahan
memakai, dan murah, keunggulan-keunggulan yang belum dapat
ditawarkan oleh produk kompetitor lain.
Konsep invensi produk lantai keramik ini menggunakan
lapisan Polyurethane yang memiliki tautan silang khusus
30 dengan 1,4-butanediol (BDO) dan Dibutylin dilaurate (DBTDL)
sehingga memiliki kemampuan self-healing. Lapisan ini yang
akan melindungi lantai keramik dari goresan karena dapat
115
menyembuhkan diri sendiri. Lantai keramik ini memiliki merk
dagang ‘GrandNight’.
Uraian Singkat Gambar

5 Untuk memudahkan pemahaman mengenai inti invensi ini,
selanjutnya akan diuraikan perwujudan invensi melalui
gambar-gambar terlampir.
Gambar 1, adalah diagram alir proses pembuatan
polyurethane dengan tautan khusus.
10
Gambar 2, adalah diagram alir proses pembuatan lantai
keramik.
Gambar 3, adalah logo untuk produk GrandNight.

116
Gambar 4, adalah kemasan untuk produk GrandNight.
Uraian Lengkap Invensi

5 Seperti yang telah disebutkan pada latar belakang,
penggunaan lantai keramik merupakan bagian penting dalam
pembangunan. Walaupun penggunaannya dan perawatan yang
mudah, tetapi terkadang lantai keramik sangat rawan
terhadap goresan dan retakan. Solusi untuk menyelesaikan
10 masalah ini sudah banyak di pasaran, dan salah satunya
merupakan solusi dari kami. Mengingat kebutuhan produk
lantai keramik berkualitas tinggi di Indonesia, masih
dipenuhi oleh barang impor, menjadi kesempatan untuk
membuat produk yang berkualitas tinggi dari pabrik dalam
15 negeri.
Lantai keramik dibuat anti-gores dengan teknologi
yang disebut self-healing. Self-healing merupakan teknologi
material yang dapat menyambung kembali apabila terpotong.
Teknologi ini diimplementasikan sebagai pelindung dari
20 lantai keramik. Material yang digunakan adalah Polyurethane
117
yang sudah dimodifikasi sehingga dapat ikatan polimernya
dapat bersambung kembali. Material ini melapisi bagian atas
lantai keramik sehingga ketika tergores, yang rusak
merupakan lapisan Polyurethane.
5 Polyurethane dapat memiliki kemampuan self-healing
apabila memiliki tautan silang khusus. Dalam invensi ini,
Polyurethane yang dihasilkan menggunakan 2,4-toluene
diisocianate (TDI) sebagai segmen keras dan polieter poliol
sebagai segemen lembut, sehingga untuk selanjutnya
10 polyurethane jenis ini disebut TDI Polyurethane. Kemampuan
self-healing yang dimiliki oleh jenis Polyurethane ini
adalah kemampuan intrinsik, yang berarti kemampuan bereaksi
tidak membutuhkan zat luaran lain. Suhu yang dibutuhkan
untuk Polyurethane untuk bereaksi satu sama lain kembali
15 untuk membuat ikatan baru adalah 40◦C.
Adapun bahan baku untuk membuat lantai keramik ini
adalah: material keramik, dimetilbenzena, butil asetat,
cycloheksanoneon, 1,4-butanadiol (BDO), dibutiltin
dilaurate (DBTDL), toluena diisosinat, serta polieter
20 poliol HSH220 dan HSH330.
Invensi ini tersedia dalam fase padat di mana lapisan
Polyurethane sudah terpasang dan tidak dijual terpisah.
Produk ini memiliki beragam jenis desain tergantung jenis
batu yang digunakan sebagai material dasar lantai keramik.
25 Kemasan produk ini adalah kardus dan pengemasan dilakukan
dalam ukuran yang sama. Produk ini disebut GrandNight.
Proses manufaktur untuk GrandNight terjadi dalam dua
bagian. Bagian pertama adalah pembuatan lapisan TDI
Polyurethane. Bagian kedua adalah pelapisan lantai keramik
30 dengan TDI Polyurethane.
Tahapan pembuatan lapisan poluretan adalah sebagai
berikut.
118
Pertama, penimbangan bahan baku. Komposisi berat yang
ditimbang adalah 24,9% dimetilbenzena, 24,9% butil asetat,
12,4% cycloheksanone, 2,3% BDO, 2,3% DBTDL, 9,9% toluena
diisosinat, 20.9% polieter polyol HSH220, dan 2,3% polieter
5 polyol HSH330.
Kedua, dilakukan pencampuran dan mereaksikan material
yang sudah ditimbang. Pencampuran dan pereaksian yang
pertama adalah HSH220 dan HSH330 dengan toluene diisosinat,
yang menhasilkan campuran A. Kemudian campuran A
10 dicampurkan dengan BDO dan DBTDL menghasilkan campuran B.
Terakhir, campuran B dicampurkan dengan dimetilbenzena,
butil asetat, dan cycloheksanone yang dicampurkan pada suhu
50 °C dan direaksikan pada suhu 70°C. menghasilkan campuran
C atau TDI Polyurethane.
15 Tahapan pelapisan lantai keramik adalah sebagai
berikut.
Pertama, melakukan pemotongan berdasarkan ukuran
lantai keramik yang dihasilkan.
Kedua, melakukan pengaplikasian epoxy resin. Epoxy
20 resin berguna untuk menyamakan dan mneghaluskan lapisan
atas lantai keramik. Kebutuhan epoxy resin adalah 0,26
kg/m2.
Terakhir, melapisi lantai keramik dengan TDI
Polyurethane. Kebutuhan TDI Polyurethane adalah 0.0836
25 kg/m2.
Selanjutnya, setelah seluruh lantai keramik sudah
dilapisi TDI polyurethane, lantai keramik diperiksa kembali
kualitasnya dan dikemas ke dalama kemasan kardus.
Klaim
30 1. Suatu lantai keramik anti-gores bermerk dagang

GrandNight
119
2. Suatu lantai keramik anti-gores pada klaim 1 yang
menggunakan teknologi self-healing polyurethane untuk
melindungi lantai keramik dari goresan dan dapat
menyembuhkan goresan yang terjadi pada lapisan
5 tersebut.
3. Suatu lantai keramik anti-gores pada klaim 1 memiliki
bahan baku antara lain: 24,9% dimetilbenzena, 24,9%
butil asetat, 12,4% cycloheksanone, 2,3% BDO, 2,3%
DBTDL, 9,9% toluena diisosinat, 20.9% polieter polyol
10 HSH220, dan 2,3% polieter polyol HSH330.
4. Proses manufaktur dari lantai keramik anti-gores pada
klaim 1 memiliki dua bagian proses, yaitu pembuatan
TDI Polyurethane dan pembuatan lantai keramik dengan
TDI Polyurethane.
15 5. Proses manufaktur TDI Polyurethane seperti pada klaim
4 terdiri dari:
a. Penimbangan bahan baku.
b. Pencampuran dan mereaksi bahan baku untuk membuat
TDI Polyurethane
20 6. Proses manufaktur pembuatan lantai keramik seperti
pada klaim 4 terdiri dari:
a. Pemotongan bahan dasar keramik
b. Pengaplikasian epoxy resin
c. Pegaplikasian TDI Polyurethane
Abstrak
PROSES PEMBUATAN KERAMIK ANTI GORES MENGGUNAKAN

POLYURETHANE MELALUI MEKANISME IKATAN SILANG
Telah dihasilkan invensi berupa keramik anti gores

menggunakan polyurethane yang terdiri dari
dimetilbenzena, butil asetat, cycloheksanone, 1.4-
Butanadiol (BDO), Dibutiltin dilaurat (DBTDL), toluena
diisosinat, polieter polyol HSH220, dan polieter polyol
HSH330. Keramik anti gores ini menggunakan
mekanisme Cross-Linked Bond yang mampu
menyeimbangkan struktur yang ada pada keramik,
dengan dibantu adanya perlakuan panas maka
mobilitas rantai pada ikatan silang akan meningkat
sehingga ikatan akan terhubung kembali. Penggunaan
keramik anti gores ini dapat meningkatkan jangka
waktu pemakaian dan menghindari terjadinya
keretakan yang bisa menyebabkan keramik menjadi
pecah. Dengan adanya invensi ini, diharapkan
masalah yang berkaitan dengan goresan, keretakan,
dan mudah pecah dapat diatasi dengan cara yang
inovatif, mudah, ekonomis dan berkualitas.

Formulir Pengungkapan Invensi
Nama Inventor & Gelar :

1. Prof. Dr. Ir. Widodo Wahyu Purwanto, DEA.
2. Prof. Dr. Ing. Ir. Misri Gozan M. Tech
3. Dr. rer. nat. Ir. Yuswan Muharam M.T.
4. Dr. Ir. Dewi Tristantini, MT.
5. Afinii Nuryati
6. Alya Hafiza Vivadinar
7. Merlando Dany Saputro
8. Nadia Salsabila
9. Wulan Silvia Ramadhani
10. Zata Amalia Siregar
Judul Invensi :
“GRANDNIGHT”: KERAMIK DENGAN LAPISAN SELF-HEALING TDI POLYURETHANE
SEBAGAI ANTI GORES
Deskripsi Umum Invensi :
Invensi yang diajukan ini pada prinsipnya adalah membuat produk lantai keramik
anti gores yang tahan lama, ekonomis, aman, dan berkualitas. Pada akhirnya
produk ini akan ketertarikan masyarakat untuk menggunakan lantai keramik yang
anti gores karena keunggulan yang ditawarkan seperti tahan lama, desain yang
bervariasi, kemudahan memakai, dan murah, keunggulan-keunggulan yang belum
dapat ditawarkan oleh produk kompetitor lain.
Konsep invensi produk lantai keramik ini menggunakan lapisan Polyurethane yang
memiliki tautan silang khusus dengan 1,4-butanediol (BDO) dan Dibutylin
dilaurate (DBTDL) sehingga memiliki kemampuan self-healing. Lapisan ini yang
akan melindungi lantai keramik dari goresan karena dapat menyembuhkan diri
sendiri. Lantai keramik ini memiliki merk dagang ‘GrandNight’.
Latar Belakang Permasalahan & Solusi :
Keramik merupakan salah satu industri yang sangat cepat dalam
pertumbuhannya. Pertumbuhan pembangunan yang semakin meningkat dan
maraknya bisnis properti yang cukup mendominasi pasar lokal dan dunia serta
pergeseran selera dan kebutuhan masyarakat akan kebutuhan barang-barang
mewah merupakan faktor utama yang mendominasi akselerasi dari industri
keramik. Keramik yang mudah retak dan mudah pecah merupakan salah satu
masalah yang sering dialami di rumah, gedung, perkantoran bahkan di tempat
fasilitas umum.
Masalah ini dapat diatasi pada umumnya yaitu dengan menggantinya dengan yang
baru. Namun biasanya ada beberapa kendala yang terjadi seperti sulit dalam
pemasangannya, membutuhkan alat khusus untuk membuatnya menjadi tetap
rapih dan terlihat bagus sehingga ini menjadi permasalahan tersendiri. Ada
beberapa alternatif selain dengan menggantinya yaitu menggunakan keramik
dengan kemampuan khusus, salah satunya yaitu dengan kemampuan anti gores.
Keramik ini dapat digunakan di dalam ruangan dalam jangka waktu yang lama.
Keramik pada umumnya memiliki tekstur yang keras dan memiliki corak yang
sangat bervariatif. Namun keramik yang ada dipasaran saat ini memiliki
kelemahan yaitu tidak tahan gores. Keramik yang tahan gores sangatlah penting
karena apabila terjadi goresan kecil pada keramik secara terus menerus maka
seiring berjalannya waktu akan menimbulkan keretakan pada keramik sehingga
mudah retak dan pecah.
Keramik yang sudah ada saat ini dibuat melalui proses pembakaran pada suhu
tinggi sehingga menghasilkan tekstur keramik yang keras dan memiliki corak yang
sangat bervariatif. Produk keramik yang sudah jadi harus memenuhi standar
pembuatan keramik yang berlaku di Indonesia sehingga kermaik memiliki kualitas
yang baik dan siap untuk digunakan. Invensi yang diajukan oleh inventor adalah
penambahan polyurethane pada pembuatan keramik yang belum pernah
digunakan sebelumnya sebagai material anti gores pada keramik.
Ruang Lingkup Penerapan Invensi :
Penerapan nvensi “GrandNight” adalah sebagai keramik anti-gores yang dapat
digunakan lebih lama dalam kondisi tidak tergores sehingga estetikanya tidak
berkurang. Penggunaannya paling cocok di ruang publik yang di mana lantai
keramik sering terkenan tekanan. Akan tetapi, penggunaan untuk personal juga
tetap memungkinkan.
Kemiripan dan Perbedaan dengan Teknologi Invensi yang Telah Ada :

Paten yang sudah ada saat ini adalah “CN107936628A, Preparation Method of
Nano Ceramic Floor Coating by Adopting Nano Silica” yang dimiliki Zhang Hong,
Ding Chao, Zhu Yuwen, dan Zhao Binmu dengan nomor paten CN107936628A.

“GrrandNight” mengembangkan cara pembuatan pelapis lantai keramik dari
paten ini.
Uraian Lengkap Invensi :
Seperti yang telah disebutkan pada latar belakang, penggunaan lantai keramik
merupakan bagian penting dalam pembangunan. Walaupun penggunaannya dan
perawatan yang mudah, tetapi terkadang lantai keramik sangat rawan terhadap
goresan dan retakan. Solusi untuk menyelesaikan masalah ini sudah banyak di
pasaran, dan salah satunya merupakan solusi dari kami. Mengingat kebutuhan
produk lantai keramik berkualitas tinggi di Indonesia, masih dipenuhi oleh barang
impor, menjadi kesempatan untuk membuat produk yang berkualitas tinggi dari
pabrik dalam negeri.
Lantai keramik dibuat anti-gores dengan teknologi yang disebut self-healing. Self-
healing merupakan teknologi material yang dapat menyambung kembali apabila
terpotong. Teknologi ini diimplementasikan sebagai pelindung dari lantai keramik.
Material yang digunakan adalah Polyurethane yang sudah dimodifikasi sehingga
dapat ikatan polimernya dapat bersambung kembali. Material ini melapisi bagian
atas lantai keramik sehingga ketika tergores, yang rusak merupakan lapisan
Polyurethane.
Polyurethane dapat memiliki kemampuan self-healing apabila memiliki tautan
silang khusus. Dalam invensi ini, Polyurethane yang dihasilkan menggunakan 2,4-
toluene diisocianate (TDI) sebagai segmen keras dan polieter poliol sebagai
segemen lembut, sehingga untuk selanjutnya polyurethane jenis ini disebut TDI
Polyurethane. Kemampuan self-healing yang dimiliki oleh jenis Polyurethane ini
adalah kemampuan intrinsik, yang berarti kemampuan bereaksi tidak
membutuhkan zat luaran lain. Suhu yang dibutuhkan untuk Polyurethane untuk
bereaksi satu sama lain kembali untuk membuat ikatan baru adalah 40◦C.
Adapun bahan baku untuk membuat lantai keramik ini adalah: material keramik,
dimetilbenzena, butil asetat, cycloheksanoneon, 1,4-butanadiol (BDO), dibutiltin
dilaurate (DBTDL), toluena diisosinat, serta polieter poliol HSH220 dan HSH330.
Invensi ini tersedia dalam fase padat di mana lapisan Polyurethane sudah
terpasang dan tidak dijual terpisah. Produk ini memiliki beragam jenis desain
tergantung jenis batu yang digunakan sebagai material dasar lantai keramik.
Kemasan produk ini adalah kardus dan pengemasan dilakukan dalam ukuran yang
sama. Produk ini disebut GrandNight.

Proses manufaktur untuk GrandNight terjadi dalam dua bagian. Bagian pertama
adalah pembuatan lapisan TDI Polyurethane. Bagian kedua adalah pelapisan lantai
keramik dengan TDI Polyurethane.
Tahapan pembuatan lapisan poluretan adalah sebagai berikut.
Pertama, penimbangan bahan baku. Komposisi berat yang ditimbang adalah
24,9% dimetilbenzena, 24,9% butil asetat, 12,4% cycloheksanone, 2,3% BDO, 2,3%
DBTDL, 9,9% toluena diisosinat, 20.9% polieter polyol HSH220, dan 2,3% polieter
polyol HSH330.
Kedua, dilakukan pencampuran dan mereaksikan material yang sudah ditimbang.
Pencampuran dan pereaksian yang pertama adalah HSH220 dan HSH330 dengan
toluene diisosinat, yang menhasilkan campuran A. Kemudian campuran A
dicampurkan dengan BDO dan DBTDL menghasilkan campuran B. Terakhir,
campuran B dicampurkan dengan dimetilbenzena, butil asetat, dan
cycloheksanone yang dicampurkan pada suhu 50 °C dan direaksikan pada suhu
70°C. menghasilkan campuran C atau TDI Polyurethane.
Tahapan pelapisan lantai keramik adalah sebagai berikut.
Pertama, melakukan pemotongan berdasarkan ukuran lantai keramik yang
dihasilkan.
Kedua, melakukan pengaplikasian epoxy resin. Epoxy resin berguna untuk
menyamakan dan mneghaluskan lapisan atas lantai keramik. Kebutuhan epoxy
resin adalah 0,26 kg/m2.
Terakhir, melapisi lantai keramik dengan TDI Polyurethane. Kebutuhan TDI
Polyurethane adalah 0.0836 kg/m2.
Selanjutnya, setelah seluruh lantai keramik sudah dilapisi TDI polyurethane, lantai
keramik diperiksa kembali kualitasnya dan dikemas ke dalama kemasan kardus.
Dokumen Pendukung :
[1]Y. Zhang, Y. Qi and Z. Zhang, "The influence of 2,4-toluene diisocyanate content
on the intrinsic self-healing performance of polyurethane at room-
temperature", Journal of Polymer Research, vol. 22, no. 5, 2015. Available:
10.1007/s10965-015-0744-0.
Kata Kunci Invensi :
self-healing, keramik, polyurethane, pelapis, anti-gores

Bidang Teknik Invensi :
Invensi ini berhubungan dengan pembuatan keramik untuk peningkatan faktor
keberlanjutan penggunaan, khususnya untuk pengguna yang ingin membangun
bangunan dengan tingkat pengunjung tinggi.
Penelitian Invensi yang Sedang Dilaksanakan :
Proporsi Kontribusi Atas Pembuatan Invensi :

11. Prof. Dr. Ir. Widodo Wahyu Purwanto, DEA. (8,5%)
12. Prof. Dr. Ing. Ir. Misri Gozan M. Tech (8,5%)
13. Dr. rer. nat. Ir. Yuswan Muharam M.T. (8,5%)
14. Dr. Ir. Dewi Tristantini, MT. (8,5%)
15. Afinii Nuryati (11%)
16. Alya Hafiza Vivadinar (11%)
17. Merlando Dany Saputro (11%)
18. Nadia Salsabila (11%)
19. Wulan Silvia Ramadhani (11%)
20. Zata Amalia Siregar (11%)

REFERENCES
Ando, K., Takahashi, K. and Osada, T. (2014). Structural ceramics with self-healing
properties. Handbook of Smart Coatings for Materials Protection, pp.586-
605.
Badan Pendapatan Daerah Cilegon. (2018). Website Pajak Bumi dan Bangunan.
[Online] Available at: http://pbb.cilegonkota.go.id/pbbh/tarifpbb.
[Accessed 5 May 2019]
Courses.lumenlearning.com. (2019). Research & Development Cost | Boundless

Accounting. [online] Available at:
https://courses.lumenlearning.com/boundless-accounting/chapter/research-
development-cost/ [Accessed 8 May 2019].
Direktorat Jenderal Kekayaan Intelektual Kementerian Hukum dan Hak Asasi
Manusia. (2016). PNBP Paten Berdasarkan PP No. 45 Tahun 2016. [Online]
Available at: http://www.dgip.go.id/tarif-paten. [Accessed 8 May 2019]
Ghosh, S. (2009). Self-healing Materials : Fundamental, Design Strategies, and
Application. Weinheim: WILEY-VCH Verlag GmbH & Co. KGaA.
Iqbal, M. (2019). Tarif Baru Pelabuhan Merak Mulai Berlaku Hari Ini. [online]
detiknews. Available at: https://news.detik.com/berita/3500681/tarif-baru-
pelabuhan-merak-mulai-berlaku-hari-ini [Accessed 10 May 2019].
Joel, Levitt. The Handbook of Maintenance Management 2nd edition. Industrial
Press, Inc at New York, USA. 1952: 43-45
Onlinelibrary.wiley.com. (2018). [online] Available at:
https://onlinelibrary.wiley.com/doi/pdf/10.1002/9783527611119.app4
[Accessed 6 May 2019]

Appendices A. Raw Material Suppliers
Table A.1 Raw Material Supplier A
Supplier A
Transportation
Travel
Raw Material Fee/unit (IDR/kg or Price/unit (IDR/kg or
Location Supplier Company Time
IDR/cbm or IDR/cbm)
(days)
IDR/shipping)
Kepulauan Riau,
Granite PT Wira Penta Kencana 3 Rp 500,000.00 Rp 500,000.00
Indonesia
Epoxy resin Banten, Indonesia PT Kreasi Inspirasi Sahabat 2 Rp 25,000.00 Rp 71.14
Dimethylbenzene Jakarta, Indonesia PT. Graha Jaya Pratama Kinerja 2 Rp 25,000.00 Rp 15,500.00
Butyl acetate Jakarta, Indonesia PT. Graha Jaya Pratama Kinerja 2 Rp 25,000.00 Rp 25,000.00
Cyclohexanone Jakarta, Indonesia PT. Graha Jaya Pratama Kinerja 2 Rp 25,000.00 Rp 17,500.00
1.4-butanediol (BDO) Banten, Indonesia PT. Insoclay Acidatama Indonesia 2 Rp 25,000.00 Rp 1,500,000.00
Dibutylin dilaurate Shenyu (Shandong) Energy
Shandong, China 14 Rp 4,500,000.00 Rp 213,562.50
(DBTDL) Development Co., Ltd.
Toluene diisocynate Jakarta, Indonesia PT. Graha Jaya Pratama Kinerja 2 Rp 25,000.00 Rp 145,000.00
Polyether polyol HSH220 Guangdong, China Zilibon Chemical Co., Ltd, China 14 Rp 4,500,000.00 Rp 284,710.00
Polyether polyol HSH330 Guangdong, China Zilibon Chemical Co., Ltd, China 14 Rp 4,500,000.00 Rp 284,710.00
Cardboard box Surabaya CV. KartonBox 3 Rp 66,964.00 Rp 3,500.00

Table A.2 Raw Material Supplier B
Supplier B
Raw Material Travel Time Transportation
Location Supplier Company Price/unit (IDR/kg)
(days) Fee/unit (IDR/kg)
Granite - - - - -
Shandong Qichen New
Epoxy resin Shandong, China 14 Rp 30,000.00 Rp 86.89
Building MaterialCo., Ltd
Shenyu (Shandong) Energy
Dimethylbenzene Shandong, China 14 Rp 30,000.00 Rp 11,390.00
Development Co., Ltd.
Butyl acetate Shandong, China 14 Rp 30,000.00 Rp 24,203.75
Shenyang East Chemical
Cyclohexanone Shenyang, China 14 Rp 30,000.00 Rp 15,662.35
Science-Tech Co., Ltd.
1.4-butanediol (BDO) Shandong, China 14 Rp 30,000.00 Rp 1,423,749.50
Dibutylin dilaurate (DBTDL) - - - - -
Liaoning, China Dalian Tianxinlongyuan Import
Toluene diisocynate 14 Rp 30,000.00 Rp 142,370.00
(Mainland) And Export Co., Ltd.
Polyether polyol HSH220 - - - - -
Polyether polyol HSH330 - - - - -
Cardboard box - - - - -
Appendices B. Raw Material Order Quantity
Table B.1 Raw Material Order and Cost per Package
Material Material Delivery Delivery Safety

Price/package A Price/package B Order/ Order/ Package/ Package/
Raw Material covered by covered by Cost/order (A) Cost/order (B) Inventory
(IDR) (IDR) year (A) year (B) order (A) order (B)
A (kg/cbm) B (kg/cbm) (IDR) (IDR) (kg)
Granite Rp 2,500,000.00 - 27720 - 6 - 924 - Rp 500,000.00 - 924
Epoxy Resin Rp 1,750,044,000.00 Rp 2,606,700.00 61414.65 3232.35 2 2 2 54 Rp 246,000,000.00 Rp 20,000,000.00 47157
Dimethylbenzene Rp 46,500.00 Rp 11,390,000.00 4299.75 1433.25 12 2 120 1 Rp 1,800,000.00 Rp 20,000,000.00 859
Butyl acetate Rp 75,000.00 Rp 24,203.75 4299.75 1433.25 12 2 120 717 Rp 1,800,000.00 Rp 20,000,000.00 236
Cyclohexane Rp 52,500.00 Rp 15,662,350.00 2151 717 12 1 60 1.00 Rp 900,000.00 Rp 20,000,000.00 348

1,4-
Rp 1,500,000.00 Rp 1,423,749.50 407.25 135.75 12 1 34 136 Rp 170,000.00 Rp 20,000,000.00 35
butanediol(BDO)
Dibutylin dilaurate
Rp 5,339,062.50 - 543 - 1 - 22 - Rp 20,000,000.00 - 117
(DBTDL)
Toluene diisocynate Rp 435,000.00 Rp 142,370.00 1721.25 573.75 12 1 48 574 Rp 720,000.00 Rp 20,000,000.00 151
Polyether polyol
Rp 284,710.00 - 4815 - 5 - 963 - Rp 20,000,000.00 - 193
HSH220
Polyether polyol
Rp 284,710.00 - 534 - 1 - 534 - Rp 20,000,000.00 - 107
HSH330
Cardboard box Rp 7,000,000.00 - 120000 - 1 - 60 - Rp 300,000.00 - 24000

Appendices C. Raw Material Cost
Table C.1 Raw Material Cost

Pack Pack Delivery
Order Order Total Cost Delivery Cost Total Delivery
per per Total Cost per Total Cost per Cost per
Raw Materials A per B per per order B per order B Cost per Year
order order order A (IDR) Year (IDR) order A
year year (IDR) (IDR) (IDR)
A B (IDR)
Granite 6 - 924 - 13,860,000,000 - 13,860,000,000 500,000 - 3,000,000
Epoxy resin 2 2 2 54 7,000,176,000 281,556,000 7,281,732,000 246,000,000 20,000,000 532,000,000
Dimethylbenzene 12 2 120 1 66,960,000 22,780,000 89,740,000 1,800,000 20,000,000 61,600,000
Butyl acetate 12 2 120 717 108,000,000 34,708,536 142,708,536 1,800,000 20,000,000 61,600,000
Cyclohexanone 12 1 60 1 37,800,000 11,276,892 49,076,892 900,000 20,000,000 30,800,000
1.4-butanediol
12 1 34 136 612,000,000 193,630,000 805,630,000 170,000 20,000,000 22,040,000
(BDO)
Dibutylin dilaurate
1 - 22 - 117,459,386 - 117,459,386 20,000,000 - 20,000,000
(DBTDL)
Toluene
12 1 48 574 250,560,000 81,720,380 332,280,380 720,000 20,000,000 28,640,000
diisocynate
Polyether polyol
5 - 963 - 1,370,878,650 - 1,370,878,650 20,000,000 - 100,000,000
HSH220
Polyether polyol
1 - 534 - 152,035,140 - 152,035,140 20,000,000 - 20,000,000
HSH330
Cardboard box 1 - 60 - 420,000,000 - 420,000,000 300,000 - 300,000
TOTAL 24,621,540,984 TOTAL 879,980,000

Appendices D. Utility Cost Breakdown
Table D.1 Main Equipment Utility Cost
Working Total Total

Equipment Qty Power Total cost/year
Time/day Power/day Power/year
Granite Stone lifting machine 1 0.125 1.50 0.1875 56.25 Rp 62,550.00
The Spreader Bar 1 0.125 0.50 0.0625 18.75 Rp 20,850.00
Gangsaw Machine 1 2.738 6.00 16.425 4927.5 Rp 5,479,380.00
Lift Arms Granite Cutting Machine 1 1.542 6.00 9.25 2775 Rp 3,085,800.00
Automatic polishing machine for granite 6.458 6.00 38.75 11625 Rp 12,927,000.00
Superline for Epoxy resin 1 1.708 6.00 10.25 3075 Rp 3,419,400.00
Digital Bench Weighing scale 1 0.167 1.50 0.2505 75.15 Rp 83,566.80
CSTR 1.380 1.00 1.38 414 Rp 460,368.00
Total Rp 25,538,915
Table D.2 Supporting Equipment Utility Cost
Working Total Total

LED Lamps 30 0.004 24 0.096 28.8 Rp 32,025.60
Fan 3 0.075 10 0.75 225 Rp 250,200.00
Dispenser 3 0.35 24 8.4 2520 Rp 2,802,240.00
Internet Upkeep 1 0.004 10 0.04 12 Rp 13,344.00
Interphone 1 0.009 10 0.09 27 Rp 30,024.00

Table D.2 Supporting Equipment Utility Cost (continued)
Working Total Total

CCTV Set (6 pcs) 1 0.025 24 0.6 180 Rp 200,160.00
Telephone 3 0.1 10 1 300 Rp 333,600.00
Faximailes 1 0.1 10 1 300 Rp 333,600.00
Projector Set 1 0.4 10 4 1200 Rp 1,334,400.00
Air Conditioner 2 1.92 10 19.2 5760 Rp 6,405,120.00
Desktop Computers 10 0.3 10 3 900 Rp 1,000,800.00
Photocopy, Printer and Scanner Machine 2 0.5 10 5 1500 Rp 1,668,000.00
Television 1 0.036 10 0.36 108 Rp 120,096.00
Absence Machine 1 0.001 24 0.024 7.2 Rp 8,006.40
Total Rp 14,531,616.00
Table D.3 Water Utility Cost

Water needs per
Type Qty m3 per year Total water cost per year
Qty per day
Employee 80 0.04 960 Rp 9,120,000.00
Process Water 369 0.0005 55.284 Rp 525,198.00
Total Rp 9,645,198.00

Table D.4 Diesel Utility Cost
Diesel needs
L per
Equipment Qty per Qty per total diesel cost per year
year
day
Generator 1 54.48 16344 Rp 215,286,763.68
Forklift 1 1.0823 324.7 Rp 4,277,019.83
Total Rp 219,563,783.51
Table D.5 Total Utility Cost
Type Cost/year
Equipment Electricity Rp 25,538,915
Supporting Faclities Electricity Rp 14,531,616.00
Water Rp 9,645,198.00
Diesel Rp 219,563,783.51
Total Rp 269,279,512

Appendices E. Loan Interest
Table E.1 Calculation of Loan Interest from Bank

Loan left after
Year Initial Loan Loan Interest Loan Payment Total Payment
payment
0 IDR 22,516,208,880 - - - IDR 22,516,208,880
1 IDR 22,516,208,880 IDR 2,195,330,366 IDR 4,503,241,776 IDR 6,698,572,142 IDR 18,012,967,104
4 IDR 9,006,483,552 IDR 878,132,146 IDR 4,503,241,776 IDR 5,381,373,922 IDR 4,503,241,776
5 IDR 4,503,241,776 IDR 439,066,073 IDR 4,503,241,776 IDR 4,942,307,849 IDR 0
Table E.2 Calculation of Loan Interest from Investor
Loan left after

Year Initial Loan Loan Interest Loan Payment Total Payment
payment
0 IDR 33,774,313,320 IDR 33,774,313,320
5 IDR 6,754,862,664 IDR 709,260,580 IDR 6,754,862,664 IDR 7,464,123,244 IDR 0

Appendices F. Product Cash Flow
Product Product
Product Price Product Price Maintenance
Year sold (m2 sold (m2 Revenue Opex
60 x 60 (IDR) Cost
60 x 60) 100 x 100)
0 2020 0 IDR 0 0 0 IDR 0 IDR 0 IDR 0
1 2021 77760 IDR 350,000 72000 Rp 480,000.00 IDR 61,776,000,000 IDR 41,289,194,478 IDR 734,195,915
2 2022 84240 IDR 350,000 78000 Rp 480,000.00 IDR 66,924,000,000 IDR 41,289,194,478 IDR 734,195,915
3 2023 90720 IDR 350,000 84000 Rp 480,000.00 IDR 72,072,000,000 IDR 41,289,194,478 IDR 734,195,915
4 2024 103680 IDR 350,000 96000 Rp 480,000.00 IDR 82,368,000,000 IDR 41,289,194,478 IDR 734,195,915
5 2025 116640 IDR 350,000 108000 Rp 480,000.00 IDR 92,664,000,000 IDR 41,289,194,478 IDR 734,195,915
6 2026 116640 IDR 350,000 108000 Rp 480,000.00 IDR 92,664,000,000 IDR 41,289,194,478 IDR 734,195,915
7 2027 116640 IDR 350,000 108000 Rp 480,000.00 IDR 92,664,000,000 IDR 41,289,194,478 IDR 734,195,915
8 2028 116640 IDR 350,000 108000 Rp 480,000.00 IDR 92,664,000,000 IDR 41,289,194,478 IDR 734,195,915
9 2029 116640 IDR 350,000 108000 Rp 480,000.00 IDR 92,664,000,000 IDR 41,289,194,478 IDR 734,195,915
10 2030 116640 IDR 350,000 108000 Rp 480,000.00 IDR 92,664,000,000 IDR 41,289,194,478 IDR 734,195,915

Gross Profit/Before
Year Depreciation Cash Expenses Loan Interest All expenses
Tax Cash Flow
0 2020 IDR 0 IDR 0 IDR 0 IDR 0 -IDR 56,290,522,200
1 2021 IDR 648,621,468 IDR 59,023,128,098 IDR 16,999,737,704 IDR 59,671,749,566 IDR 2,752,871,902
6 2026 IDR 408,557,953 IDR 42,023,390,394 IDR 0 IDR 42,431,948,347 IDR 50,640,609,606

Net Profit After
Taxable Income/Net Cumulative After
Year Income Tax Tax/After Tax Cash
Profit Before Tax Tax Cash Flow
Flow
0 2020 -IDR 56,290,522,200 -IDR 56,290,522,200 IDR 0 -IDR 56,290,522,200 -IDR 56,290,522,200
1 2021 IDR 2,104,250,434 IDR 526,062,608.39 IDR 526,062,608 IDR 2,226,809,293 -IDR 54,063,712,907
2 2022 IDR 8,458,770,893 IDR 2,114,692,723.32 IDR 2,114,692,723 IDR 6,934,505,831 -IDR 47,129,207,075
5 2025 IDR 37,786,784,603 IDR 9,446,696,150.64 IDR 9,446,696,151 IDR 28,787,482,363 IDR 13,516,856,912

TK23 - Final Report

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UNIVERSITAS INDONESIA

SELF-HEALING CERAMICS FLOOR

AFINII NURYATI (1606871455)

CHEMICAL ENGINEERING DEPARTMENT

LIST OF GROUP MEMBER

1. Name : Afinii Nuryati

2. Name : Alya Hafiza Vivadinar

3. Name : Merlando Dany Saputro

4. Name : Nadia Salsabila

5. Name : Wulan Silvia Ramadhani

6. Name : Zata Amalia Siregar

Depok, 17th May 2019

SELF-HEALING CERAMICS FLOOR

Keywords: self-healing, ceramics, polyurethane, coating, anti-scratch.

LIST OF GROUP MEMBER .............................................................................. ii

viii Universitas Indonesia

Figure 1. 1 Example of ceramics application for housing purposes ................. 2

Figure 2. 1 Existing concept of ceramics healing ............................................. 14

Figure 3. 1 Logo of the products ........................................................................ 32

Figure 4. 1 GDP of Indonesia in 2000-2017 ...................................................... 35

Figure 5. 1 Raw Material Inventory Chart per day......................................... 64

Figure 6. 1 Curve of Marshall & Swift Index Value ........................................ 72

Table 1. 1 Grouping needs .................................................................................... 6

Table 2. 1 List of concept screening ................................................................... 18

Table 4. 1 Commercial Demand Percentage from Indonesia Ceramics Tiles

Table 5. 1Product Distribution Location and Capacity .................................. 65

Table 6. 1 Forecasting Marshall & Swift Index Value .................................... 72

Table 7. 1 Payback Period Calculation ............................................................. 99

xiii Universitas Indonesia

Appendices A. Raw Material Suppliers .......................................................... 127

xiv Universitas Indonesia

1.1 Background of Ideas

1.2 Problem Identification

Figure 1. 1 Example of ceramics application for housing purposes

1.3.3. Making Process of Ceramics Floor

1.3.5. Today’s Trends

Table 1. 1 Grouping needs

1.4.4 Needs Ranking

Table 1. 3 Needs ordered by rank

1.4.5 Metric and Needs Grouping

%WA (Water Absorption)

%WA (Water Absorption)

Table 1. 6 List of Benchmarking (Continued)

2.1 Concept Generation (Existing, New, Combined)

Figure 2. 1 Existing concept of ceramics healing

2.1.2 New Concept

Figure 2. 2 New concept of ceramics healing

2.1.3 Concept Generation

Figure 2. 3 Generating concept of ceramics healing

2.2.1 Concept Screening

Table 2. 1 List of concept screening

Table 2.1 List of concept screening (continued)

Table 2.1 List of concept screening (continued)

Criteria H LI LV LVI LVII LVIII LIX LX

2.2.2 Concept Scoring

Table 2. 2 Judgment score based on saaty's pairwase comparison index

Judgment Score based on Saaty's Pairwase Comparison Index

Brief description of each criterion is discussed as follows.

2.2.2.2 Ranking the Concept

Table 2. 3 Description of Rating Score

2.2.2.3 Ranking the Concept

𝒓𝒊𝒋 = 𝒓𝒂𝒘 𝒓𝒂𝒕𝒊𝒏𝒈 𝒇𝒐𝒓 𝒄𝒐𝒏𝒄𝒆𝒑𝒕 𝒋 𝒇𝒐𝒓 𝒊𝒕𝒉 𝒄𝒓𝒊𝒕𝒆𝒓𝒊𝒐𝒏