10 IMPROVEMENT REGISTER 2022

Nama Gebi Muslimah M. Up to date

O O Quality
issue

CATEGORY
NIK 22180196

THEME
Dept/Sect PE-Dyeing
O Project O Cost
TITLE IMPROVEMENT :
Project of Switching Chemical for Improve by
Delivery
R/C Process self
Background

In October 2020, YKK Zipco used 3 chemicals for RC and one of them
(Reducing Agent) is still manual process.
This project is continued project from 2021.

Goals or Target

1. Switching powder chemical into liquid chemical

Estimation Start Improvement

Estimation Finish Improvement

Approved Check by Prepared By

( ) ( ) ( )
INVESTMENT EFFECFor TTL CosAnnual Effect
Remarks
(ロ×12)
#VALUE! Cost Reduction/合理化フォーム
0 40,410 DO NOT DELETE!!
INVESTMENT EFFEC###

FY 2020 Effect Calculation For

Kategori Tema Penggantian Chemical
kelompok NCA Tujuan / Isi Menyederhanakan pro
Negara ( untuk mata uang ) Indonesia
Nama perusahaan YKK Zipco
No M/C No.
Department CF CHAIN
Section Dyeing 1
M/C Data
Section No. 2
Nama penanggung jawa 3
Lokasi produksi 4
Re-located from 5
M&E M/C Inst. C Mata Uang 6
Klasifikasi tema 4 USD TTL

Prod Plan（kg./mo） 750

Project No.(Japan) Payback Period 0.0

<Perhitungan kapasitas M/C dan Jumlah yg di perlukan>
A: M/C yg ada (20 hari kerja

Kapasitas

Kebutuhan Qty

< Effect investasi> Perhitungan biaya proses

Category A: Existing Recipe (1 working days/shot.) [Before

Material cost
Material cost

TTL

Labor Cost

TTL

Outsoursing
Cost
TTL

USD/kg g/L L/Shot

NaOH (25%) 0.30 x 4.00 x 2000
Sub-material Escudo P-770 1.29 x 0.50 x 2000
Cost Reducing Agent 6.60 x 0.50 x 2000
Dyeing Acid AF 0.85 x 0.30 x 2000

TTL

M/C parts Cost

TTL

Electricity Cost
TTL

Overhead Cost
TTL

Service Dept.
Cost
TTL

Interests

Mata Uang
USD
TTL (kecuali depresiasi)

Depresiasi
(Jumlah tetap)
 Mata Uang
USD
TTL ( Termasuk Bunga )
TTL (Bunga tidak termasuk)
Amount of Production Precondition:

kg APR MAY JUN JUL AUG

Plan 750 750 750 750 750
Actual
Actual / Plan （%） 0% 0% 0% 0% 0%
Amount of Effect *Plan (Based on Act) = Planned effect per unit x Actual amount of productio

USD APR MAY JUN JUL AUG

Plan 3,368 3,368 3,368 3,368 3,368
Plan (based on Act) A 0 0 0 0 0
Actual B 0 0 0 0 0
Plan - Act (B-A)
Act / Plan（%） 0% 0% 0% 0% 0%

Planned Reduction Cost (Monthly summary)

USD APR MAY JUN JUL AUG

Material Cost 0.0 0.0 0.0 0.0 0.0
Labor Cost 0.0 0.0 0.0 0.0 0.0
Outsourcing Cost 0.0 0.0 0.0 0.0 0.0
Sub Material Cost 3367.5 3367.5 3367.5 3367.5 3367.5
Machine Parts Cost 0.0 0.0 0.0 0.0 0.0
Electricity Cost 0.0 0.0 0.0 0.0 0.0
Overhead Cost 0.0 0.0 0.0 0.0 0.0
Service Dept. Cost 0.0 0.0 0.0 0.0 0.0
Depreciation Cost 0.0 0.0 0.0 0.0 0.0
s.ttl 3367.5 3367.5 3367.5 3367.5 3367.5
Actual of Reduction cost / unit (Monthly summary)
USD APR MAY JUN JUL AUG
Material Cost 0 0 0 0 0
Labor Cost 0 0 0 0 0
Outsourcing Cost 0 0 0 0 0
Sub Material Cost 0 0 0 0 0
Machine Parts Cost 0 0 0 0 0
Electricity Cost 0 0 0 0 0
Overhead Cost 0 0 0 0 0
Service Dept. Cost 0 0 0 0 0
Depreciation Cost 0 0 0 0 0
 s.ttl 0 0 0 0 0

Reduced man-day
Man-day APR MAY JUN JUL AUG
Plan 0 0 0 0 0
Actual 0 0 0 0 0

pcs
Mpcs
MMpcs
kg
ton
ms
kms
md
kmd
m2
km2
m3
culation Form (Common) Unit Mata uang dan
jumlah

enggantian Chemical Untuk R/C process

enyederhanakan proses dengan sistem automatisasi dan penurunan biaya penggunaan zat pembantu teksti
M/C yang ada M/C Baru
Unit Price TTL Cost
M/C No. M/C Name MC Qty No M/C No. M/C Name
(USD) (USD)

1
2
3
4
5
6
TTL 0 TTL

750 750

yrs.(Rumus calculasi） (a. Jumlah investasi + Biaya lain-lain） / （b. Jumlah pengurangan biaya kecuali penyusutan X

C yg ada (20 hari kerja/bulan.)

Efficiency %

ng days/shot.) [Before]
USD/mo USD/kg
defective rate %
 0.0 0.0
0.0 TTL
inspection
man-days/mo
0.0

0.0 0.00
0.0 TTL

0.0 0.0
0.0 TTL
Shot/ USD/
month month
x 750 = 1800000 1800.00
x 750 = 967500 967.50
x 750 = 4950000 4950.00
8,100 10.8
x 750 = 382500 382.50

8100.00 TTL

0.0 0.0
0.0 TTL

0.0 0.0
0.0 TTL

0.0 0.0
0.0 TTL

0.0 0.0
0.0 TTL

0.0 0.00

8,100 10.8

0.0 0.00
 0.0 0.00

8,100.0 10.80
8,100.0 10.80

2022
SEP OCT NOV DEC JAN FEB MAR TTL
750 750 750 750 750 750 750 9,000
0
0% 0% 0% 0% 0% 0% 0% 0%
tual amount of production
2022
SEP OCT NOV DEC JAN FEB MAR TTL
3,368 3,368 3,368 3,368 3,368 3,368 3,368 40,410
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0
0% 0% 0% 0% 0% 0% 0% 0%

2022
SEP OCT NOV DEC JAN FEB MAR TTL
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
3367.5 3367.5 3367.5 3367.5 3367.5 3367.5 3367.5 40410.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
3367.5 3367.5 3367.5 3367.5 3367.5 3367.5 3367.5 40410.0

2022
SEP OCT NOV DEC JAN FEB MAR TTL
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
 0 0 0 0 0 0 0 0

2022
SEP OCT NOV DEC JAN FEB MAR TTL
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
 Silahkan isi jika tidak ada dal
Mata uang dan
jumlah 1 USD Qty. kg 2019.04

Currency amou
Untuk investasi bis0 No.
zat pembantu tekstil
M/C Baru (Plan) M/C Baru(Actual)
Unit Price TTL Cost
M/C Name MC Qty No M/C No. M/C Name MC Qty
(USD) (USD)

1
2
3
4
5
6
(a) 0 TTL

750

kecuali penyusutan X 12 Bulan） ＝ X.X yrs Effec tahun (ロ×12) USD

B: (Plan) mesin baru (20 hari kerja/bulan.)

B :New recipe (1 working days/shot.) [After]

 0

Shot/
USD/ month
USD/kg g/L L/shot month
NaOH (25%) 0.30 x 2.00 x 2000 x 750 = 900000 900
Escudo RC-1567 2.30 x 1.00 x 2000 x 750 = 3450000 3450

Dyeing Acid AF 0.85 x 0.30 x 2000 x 750 = 382500 382.5

 Business Plan-Exchange Rate Yen USD
TTL AVE USD 110.0 1.0
9,000 750 Yen 1.0 0.01
0 0 USD 105.0 1.0
0% 0%
yyyy/mm Effect-valid months
Planned Comp. Month
TTL AVE Act Comp. Month
40,410 3,368 Effect Theme OK
0 0
0 0 Section No.
0 0 Affected sections
0% 0%

DO NOT DELETE!!
FYBusiness plan exchange r
TTL AVE Effect per unit Proportion Area Country Name
0.0 0.0 0.0 0% Material Cost JAPAN JAPAN
0.0 0.0 0.0 0% Labor Cost NORTH AND U.S.A
0.0 0.0 0.0 0% Outsourcing Cost CENTRAL CANADA
40410.0 3367.5 4.5 100% Sub Material Cost AMERICA MEXICO
0.0 0.0 0.0 0% Machine Parts Cos HONDURAS
0.0 0.0 0.0 0% Electricity Cost EL SALVADOR
0.0 0.0 0.0 0% Overhead Cost COSTA RICA
0.0 0.0 0.0 0% Service Dept. Cos TRINIDAD &
0.0 0.0 0.0 0% Depreciation Cost COLOMBIA
40410.0 3367.5 4.5 100.0% SOUTH BRAZIL
AMERICA CHILE
ARGENTINE
TTL AVE Effect per unit Proportion EMEA NETHERLAND
0 0.0 0.0 0% Material Cost U.K.
0 0.0 0.0 0.0% Labor Cost NORWAY
0 0.0 0.0 0.0% Outsourcing Cost SWEDEN
0 0.0 10.8 100.0% Sub Material Cost FINLAND
0 0.0 0.0 0.0% Machine Parts Cos IRELAND
0 0.0 0.0 0.0% Electricity Cost DENMARK
0 0.0 0.0 0.0% Overhead Cost RUSSIA
0 0.0 0.0 0.0% Service Dept. Cos GERMANY
0 0.0 0.0 0.0% Depreciation Cost POLAND
 0 0.0 10.8 100.0% BELGIUM
FRANCE
MOROCCO
CZECH
TTL AVE AUSTRIA
0 0 ROMANIA
0 0.0 SWITZERLAN
ITALY
SPAIN
PORTUGAL
GREECE
TURKEY
LEBANON
TUNISIA

EGYPT

KENYA
SWAZILAND
UKRAINE
ISRAEL
ETHIOPIA
CHINA CHINA
HONG KONG
MACAU
ASIA SINGAPORE
MYANMAR

VIET NAM

THAILAND
PHILIPPINES
MALAYSIA
INDONESIA

PAKISTAN

INDIA
BANGLADESH

SRILANKA

KOREA
TAIWAN
AUSTRALIA
FIJI
NEW ZEALAN
hkan isi jika tidak ada dalam daftar
2019.04 Tanggal Mulai Tanggal Peru
Currency amount USD
Purpose Category
Tujuan investasi
E Peningkatan keuntunga
Actual)
Unit Price TTL Cost
(USD) (USD) * Isi bagian ini jika anda adalah perusaan yg dituju
0 Pilot item 1 / Rasio produksi
Rasio produksi barang sample
0
(kecuali bagian umum )
0
0
0 * Isi bagian ini jika anda adalah perusaan yg dituju
0 Item 1 / Ratio
(c) 0 Rasio produksi barang sample
(bagian umum)

USD 40,410

Exist - Plan (B-A) D

Efficiency % Efficiency %

0.0

C :Reduced cost (A-B) D

USD/mo USD/kg USD/mo USD/kg
defective rate % defective rate %
0.0
 0.0 0.0 0.0 0.0
0.0 TTL
inspection inspection
man-days/mo man-days/mo
0.0

0.0 0.00 0.0 0.00

0.0 TTL

0.0 0.0 0.0 0.0

0.0 TTL

4733 6.3 3,367.5 4.5

4733 TTL

0.0 0.0 0.0 0.0

0.0 TTL

0.0 0.0 0.0 0.0

0.0 TTL

0.0 0.0 0.0 0.0

0.0 TTL

0.0 0.0 0.0 0.0

0.0 TTL
Unit pric

0.0 0.00 0.0 0.00 Machine

Die set
TTL
4,733 6.31 ロ 3,367.5 4.49
Machine
Dieset

Building unit
Building
(USD/sq)
0.0 0.0 0.0 0.0 0 ×
Insurance
 0.0 0.0 0.0 0.0

0
TTL
4732.5 6.31 3,367.50 4.49
4732.5 6.31 3,367.50 4.49
* Tambahkan item ke daftar di bawah ini jika diperlukan
USD Biaya satuan STD UNIT
1.0 Biaya tenaga kerja USD/Man-day
0.01 Biaya listrik USD /KWH
1.0 Biaya air USD /ｍ3
Biaya bahan bakar USD /ｍ3
Effect-valid months Biaya Bangunan USD /㎡
Biaya uap
Biaya Udara
Interest of Machine 4.0 % (YKK G-unified value)
Tahun depresiasi mesin 8 Year
No. Tahun depresiasi bangunan 30 Year

DO NOT DELETE!! DO NOT DELETE!! DO NOT DELETE!

ness plan exchange rate Currency for Table Currency for input Currency for Caluc
Country Name Currency Value of Yen JPY USD 1
JPY 1 USD 1 1.00
USD 105
CAD 79.2
MXN 5.33 DO NOT DELETE!!
HONDURAS HNL 4.25 Currency
EL SALVADORUSD 105 1000EUR 120000
COSTA RICA CRC 0.183 1000USD 105000
TRINIDAD & TTD 15.6 1000CNY 14700
COLOMBIA COP 0.0308 1000YEN 1000
BRL 25.5
CLP 0.146
ARGENTINE ARS 1.86
NETHERLANDEUR 120
GBP 129
NOK 11.7
SEK 10.8
EUR 120
RELAND EUR 120
DENMARK DKK 15.5
RUB 1.60
GERMANY EUR 120
PLN 26.6
 EUR 120
EUR 120
MOROCCO MAD 10.9
CZK 4.48
EUR 120
RON 24.5
SWITZERLAN CHF 106
EUR 120
EUR 120
PORTUGAL EUR 120
EUR 120
TRL 18.3
LBP 0.069
EUR 120
TND 37
USD 105
EGP 6.4
USD 105
SWAZILAND SZL 7.03
UAH 4.22
NIS 29.80
ETB 3.57
CNY 14.7
HONG KONG HKD 13.4
MOP 13.0
SINGAPORE SGD 76.0
MYANMAR USD 105
0.069
USD 105
VND 0.005
THAILAND THB 3.44
PHILIPPINES PHP 2.01
MALAYSIA MYR 25.0
NDONESIA USD 105
IDR 0.007
PAKISTAN USD 105
0.67
INR 1.47
BANGLADESHUSD 105
BDT 1.24
SRILANKA USD 105
0.58
KRW 0.088
TWD 3.37
AUSTRALIA AUD 71.4
FJD 47.9
NEW ZEALANNZD 66.7
 Verification Date
Tanggal Perubahan (Completion Date)

Category Genre Subject

ningkatan keuntungan Renewal Cost Reduction

asio produksi Pilot item 2 / Rasio Produksi Pilot item 3 / Ratio produksi

Item 2 / Ratio Item 3 / Ratio Item 4 / Ratio

D: verifikasi efek instal mesin baru (20 kerja/bulan.)

Efficiency %

D: verifikasi efek instal mesin baru (20 kerja/bulan.)

USD/mo USD/kg
Tinkat kerusakan %
 0.0 0.0
0.0
inspection
man-days/mo
10.0

0.0 0.0
0.0

0.0 0.0
0.0

0.0 0.0

0.0

0.0 0.0
0.0

0.0 0.0
0.0

0.0 0.0
0.0

0.0 0.0
0.0
TTL AMT Rate month Interest
Unit pric Quantity (USD) (%)/yr /year USD/mo
0 x 4 ÷ 12 = 0.0 0.0 0.00
USD × 台 ＝ 0 x 4 ÷ 12 = 0
0 0.0
Ini di gunakan untuk efek perhitungan investasi→ 0.0 0.00
Depreciation
Machine,Dieset month Machine depreciation
total (USD) /year USD/month
Year
0 ÷ 8 ÷ 12 = 0.0
Area Building total Depreciation month Building depreciation
(sq) (USD) Year /year USD/month
= 0 ÷ 20 ÷ 12 = 0 0.0 0.00
Fixed asset Insurance month Insurance total
total (USD) %/year /year USD/month
 0.0 0.00

0 x 2 ÷ 12 = 0.0
0.0
0.0 0.00
ini di gunakan untuk perhitungan efek dari tema pengurangan biaya→ 0.0 0.00
* Investasi lain seperti pengembangan,peningkatan,dan biaya kontruksi.

Investasi
(Biaya lain-
lain)

TTL
*Untuk jumlah efek negatif perusahaan yg sebelumnya memproduksi mendapat peraliahan dari lokasi pr

Effect Negatif

TTL

DO NOT DELETE!!
Currency for Caluculation
1 YEN→Domestic currency
1.00 Domestic currency → YEN
 【To be used for Sammary Table(
Local Rate
1USD
↓
Exchange to other rate
1000YEN

o produksi

【To be used for Sammary Table(

Local Rate
1USD
4 / Ratio Item 5 / Ratio ↓
Exchange to other rate

1000YEN

Plan - Act (B-D) Act(A-D)

Efficiency % Efficiency % Efficiency % Effect-valid months

Purpose

- -

E :mengurangi biaya(B-D) F :Pengurangan biaya(A-D)

USD/kg USD/mo USD/kg USD/mo USD/kg
nkat kerusakan % Tinkat kerusakan % Tinkat kerusakan %
0.0
 0.0 0.0

inspection inspection inspection

man-days/mo man-days/mo man-days/mo
10.0 -10.0 -10.0

0.0 0.0

0.0 0.0 Outsourcing Cost

0.0 8,100.0 11
Sub-Material Cost

0.0 0.0 MC Parts Cost

0.0 0.0 Electricity Cost

Overhead Cost
0.0 0.0

0.0 0.0 Service Dept. Cost

0.00 0.0 Interest

0.00 4,732.5 6.3 8,100.0 ニ 10.80

Depreciation
0.00 0.0
 0.00 0.0

0.00 4,732.5 6.3 8,100.0 10.80

0.00 4,732.5 6.3 8,100.0 10.80

0.0

0.0
dapat peraliahan dari lokasi produksi.

0.0

0.0
d for Sammary Table(Plan)】
ClassificationPurpose of Investment bis0 No. M&E M/C Inst. Group Company
0 Cost Reduction 0 C NCA YKK Zipco

0 Cost Reduction 0 C NCA YKK Zipco

d for Sammary Table(Actual)】

Material Labor Outsourcing Sub-Material MC parts Electricity
0.0 0.0 0.0 10.8 0.0 0.0

0.0 0.0 0.0 1.1 0.0 0.0

DO NOT DELETE!!
2019/04 2019/05 2019/06 2019/07 2019/08 2019/09
1 2 3 4 5 6

DO NOT DELETE!!
Category Genre Subject
E Profit Improvement Renewal Cost Reduction
F Profit Improvement Renewal Renewal/Replacement
 Fiscal Year Planned Effect
Dept Section Theme Planned Effect
Planned comp. Month
valid monthAct comp. Month
CF CHAINPenggantian
Dyeing Chemical Untuk R/C40,410.0
process

CF CHAINPenggantian
Dyeing Chemical Untuk R/C process
4,243.1

Overhead Service Dept Depreciation

0.0 0.0 -

0.0 0.0 0.0 ←Copy the cell of this line to Summary table (Actual), or please link

2019/10 2019/11 2019/12 2020/01 2020/02 2020/03 2020/04

7 8 9 10 11 12 11
 Amount of effect per unit USD/kg
Act Effect
valid month Material Labor Outsourcing Sub-Material MC parts Electricity Overhead
0.0 0.0 0.0 4.5 0.0 0.0 0.0

0.0 0.0 0.0 0.5 0.0 0.0 0.0

tual), or please link

2020/05 2020/06 2020/07 2020/08 2020/09 2020/10 2020/11 2020/12

10 9 8 7 6 5 4 3
 Qty unit

Service Dept Depreciation TTL TTL 4 5 6

0.0 0.0 4.5 10.8 kg 750 750 750

0.0 0.0 0.5 1.1 kg 750 750 750

2021/01 2021/02 2021/03

2 1 0
 Monthly production plan kg

7 8 9 10 11 12 1 2
750 750 750 750 750 750 750 750

750 750 750 750 750 750 750 750

 Monthly Eff

3 TTL TTL AVE 4 5 6 7

750 9,000 750 3,368 3,368 3,368 3,368

750 9,000 0 750 354 354 354 354

 Monthly Effect Plan USD

8 9 10 11 12 1 2 3
3,368 3,368 3,368 3,368 3,368 3,368 3,368 3,368

354 354 354 354 354 354 354 354

 4-3 Amount of Effect

TTL AVG Material Labor Outsourcing Sub-Material MC parts

40,410 3,368 0.0 0.0 0.0 40,410.0 0.0

4,243 354 0 0 0 4,243 0

4-3 Amount of Effect Other than common sections

Electricity Overhead Service Dept Depreciation TTL PILOT item 1 Prod. Ratio PILOT item 2
0.0 0.0 0.0 0.0 40,410.0 0 0% 0

0 0 0 0 4,243.1 0 0% 0
er than common sections Common sections

Prod. Ratio PILOT item 3 Prod. Ratio PILOT item 1 Prod. Ratio PILOT item 2 Prod. Ratio PILOT item 3
0% 0 0% 0 0% 0 0% 0

0% 0 0% 0 0% 0 0% 0
sections Theme 1.Reducing Input Index by half
classificati defective rate %
on(STD)
Prod. Ratio PILOT item 4 Prod. Ratio Before After(P） Effect(P) After(A）
0% 0 0% 4

0% 0 0% 4 0
↑
Copy & Paste to the CO, CP co
of the Summary(Actual)shee
half 2.Reduce inspection man-days by half 3.Improve overall
man-days/month
Effect(A) Before After(P） Effect(P) After(A） Effect(A) Before
0.0 0.0 10 -10.0

0 0 10
↑ ↑
Paste to the CO, CP column Copy & Paste to the CT, CU column
he Summary(Actual)sheet of the Summary(Actual)sheet
3.Improve overall equipment efficiency Project
% No.(JPN)
After(P） Effect(P) After(A） Effect(A)
0

0
↑
Copy & Paste to the CY, CZ column
of the Summary(Actual)sheet
10/30/2020

Activity Note PIC

1 2 3 4 5
ask for sample test 1 Gebi, Pak Plan
Meeting with Inkali
Kg Solikhin Actual
3CF #520; #580 Gebi, Pak Plan
[Cons: 0.65 g/L] Sardi Actual
3CF #520; #580 Gebi, Pak Plan
[Cons: 1.5 g/L] Sardi Actual
5RC #520; #580 Gebi, Pak Plan
[Cons: 0.65 g/L] Sardi Actual
Trial on 0.5K M/C
5RC #520; #580 Gebi, Pak Plan
[Cons: 1.5 g/L] Sardi Actual
5RC #FR-13, #FR-LGR Gebi, Pak Plan
[Cons: 0.65 g/L] Sardi Actual
5RC #FR-13, #FR-LGR Gebi, Pak Plan
[Cons: 1.5 g/L] Sardi Actual
CCI Value Check, Pak Sardi, Plan
Testing & Lab
Corfastness check Pak Uwin Actual
Sample Preparation for Gebi, Pak Plan
Discuss of the results 150 K M/C Trial Solikhin Actual
Gebi, Pak Plan
3CF #580 Pendi, TS
Inkali Actual
Gebi, Pak Plan
3CF #520 Pendi, TS
Inkali Actual
Gebi, Pak Plan
5RC #520 Pendi, TS
Inkali Actual
Trial on 150 K M/C Gebi, Pak Plan
5RC #580 Pendi, TS
Inkali Actual
Gebi, Pak Plan
5RC FR-13 Pendi, TS
Inkali Actual
Gebi, Pak Plan
5RC FR-LGR Pendi, TS
Inkali Actual
Pak Sardi, Plan
Testing & Lab Colorfastness check
Pak Uwin Actual
 Nov-20 Dec-20
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3
Dec-20 Schedule of switching RC chemical
4 5 End of October End of November
TANEDE Stock(kg) 4600 3610
Consume(kg) 990

RC-1567 Test by Gebi

End of Decmber End of January End of February End of March
2620 1630 640 -350
990 990 990 990
Start to use RC-1567
Discussion with INKALI Order 1 container Order 1 container
DETAIL SCHEDULE
Plan/
NO Activity Note PIC Actual
12
Setting Machine Gebi Plan
1 Preparation
(No.12) Pak Pendi Actual
Socialization to Operator Gebi Plan
2 Preparation using RC Chemical
Pak Anang Actual
Plan
3 Running Production Dyeing Team
Actual
Record PR and color Gebi Plan
4 fastness check Pak Sardi, Uwin Actual
Plan
5 Weekly Review Dyeing Team
Actual
 May
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
 June
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8
 2022
July
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
 August
28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
August
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3

Gebi:
approval MOC
 September
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Gebi:
approval sign from advisor
and management
 23 24 25 26 27 28 29 30

Gebi:
approval sign from advisor
and management
 10 IMPROVEMENT REGISTER 2021
Name Gebi Muslimah M. Up to date
O O Quality
issue

CATEGORY
NIK 22180196

THEME
Dept/Sect PE-Dyeing
O Project O Cost
TITLE IMPROVEMENT :
Project of Switching Chemical for Improve by
Delivery
R/C Process self
Monitoring

ESCUDO RC-1567

Approved Check by Prepared By

( ) ( ) ( )
 10 IMPROVEMENT REGISTER 2021
Name Gebi Muslimah M. Up to date
O O Quality
issue

CATEGORY
NIK 22180196

THEME
Dept/Sect PE-Dyeing
O Project O Cost
TITLE IMPROVEMENT :
Project of Switching Chemical for Improve by
Delivery
R/C Process self
Results
Saat ini sedang dilakukan pengetesan dengan skala produksi dan di evaluasi
setiap hari.

Approved Check by Prepared By

( ) ( ) ( )
 #580 20228 20229
MONTH Aug-22 Sep-22 TOTAL
ITEM OK NG OK NG TIMES
3CF 21 0 40 0 61
3FR 0 0 0 0 0
5CRC 0 0 0 0 0
5CI 5CI 124 1 107 0 232
5RC 5RC 82 1 45 0 128
5CP 0 0 0 0 0
45CF 6 0 8 0 14
8RC 16 0 25 0 41
10RC 10RC 22 1 14 0 37
2CC 0 0 4 0 4
2SLF 1 0 0 0 1
3EN 10 0 7 0 17
3CC 0 0 0 0 0
3LF 0 0 0 0 0
TOTAL 282 3 250 0 535
Beam Dye 150 kg
Water vo 2000 L

CURRENT R/C Process

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 4.00 8 0.30 2.40

RC Reducing Agent 0.50 1 6.60 6.60
ESCUDO P-770 0.50 1 1.29 1.29
Neut. Dyeing Acid AF 0.30 0.6 0.85 0.51
CW
TOTAL 10.8
RED

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

RC TANEDE RFH-B 2.00 4 2.38 9.52

Neut.
CW
TOTAL 9.52
 Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

RC TANEDE RFH-B 1.00 2 2.38 4.76

Neut.
CW
TOTAL 4.76

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 2.00 4 0.25 1.00

RC ESCUDO RC-1567 1.00 2 2.20 4.40

Neut. Dyeing Acid AF 0.30 0.6 0.59 0.35

CW
TOTAL 5.75
PLAN R/C Process

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 2.00 4 0.3 1.20

RC ESCUDO RC-1567 1.00 2 2.3 4.60

Neut. Dyeing Acid AF 0.30 0.6 0.85 0.51

CW
TOTAL 6.31
PLAN R/C Process RED

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 2.00 4 0.3 1.20

RC ESCUDO RC-1567 1.50 3 2.3 6.90

Neut. Dyeing Acid AF 0.30 0.6 0.85 0.51

CW
TOTAL 8.61

6271.56

CURRENT RECIPE UPDATE FROM ZIPCO

 Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 4.00 8 0.25 2.00

RC Reducing Agent 0.50 1 3.20 3.20
ESCUDO P-770 0.50 1 1.40 1.40
Neut. Dyeing Acid AF 0.30 0.6 0.59 0.35
CW
TOTAL 6.95

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 4.00 8 0.25 2.00

RC Reducing Agent 1.00 2 3.20 6.40

Neut. Dyeing Acid AF 0.30 0.6 0.59 0.35

CW
TOTAL 8.75

TEST UPDATE FROM INKALI

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 2.00 4 0.25 1.00

RC ESCUDO RC-1567 1.50 3 2.20 6.60

Neut. Dyeing Acid AF 0.30 0.6 0.59 0.35

CW
TOTAL 7.95

TEST UPDATE FROM ZIPCO

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 2.00 4 0.25 1.00

RC ESCUDO RC-1567 0.65 1.3 2.20 2.86
SUNCLEANER V-9N 0.30 0.6 2.80 1.68
Neut. Dyeing Acid AF 0.30 0.6 0.59 0.35
CW
TOTAL 5.89

TEST UPDATE FROM ZIPCO

 Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 4.00 8 0.25 2.00

RC ESCUDO RC-1567 1.00 2 2.20 4.40
SUNCLEANER V-9N 0.30 0.6 2.80 1.68
Neut. Dyeing Acid AF 0.30 0.6 0.59 0.35
CW
TOTAL 8.43

RECIPE PLAN FOR TEST

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 2.00 4 0.25 1.00

RC ESCUDO N21D-335 1.00 2 2.40 4.80
SUNCLEANER V-9N 0.30 0.6 2.80 1.68 ?
Neut. Dyeing Acid AF 0.30 0.6 0.59 0.35
CW
TOTAL 7.83
 CURRENT RC ZIPCO

COST SAVING/ Cons. Consumption

PROCESS Process Chemical
(g/L) (kg)

NaOH (25%) 2.00 4

RC ESCUDO RC-1567 1.00 2

Neut. Dyeing Acid AF 0.30 0.6

CW
-42%
CURRENT RC ZIPCO

Cons. Consumption
Process Chemical
(g/L) (kg)

NaOH (25%) 4.00 8

RC Reducing Agent 0.50 1
ESCUDO P-770 0.50 1
Neut. Dyeing Acid AF 0.30 0.6
CW
-10%

581

3664.217

2607.343
$ 31,288.12
IDR 453,677,682
 3.58620689655172

Unit
Cons. Price Cost (USD)/
Process Chemical Consumption (kg)
(g/L) (USD/kg Process
)
NaOH (25%) 2.00 4 0.25 1.00
RC ESCUDO RC-1567 1.30 2.6 2.20 5.72

Neut. Dyeing Acid AF 0.30 0.6 0.59 0.35

CW
TOTAL 7.07
 RC CMG

Cost
Unit Price Cons. Consumption Unit Price
(USD)/ Process Chemical
(USD/kg) (g/L) (kg) (USD/kg)
Process

0.30 1.20 NaOH (25%) 4.00 8 0.37

2.30 4.60 RC ESCUDO RC-1567 1.50 3 2.3

0.85 0.51 CW
Finish
TOTAL 6.31 TOTAL
PLAN RC

Cost
Unit Price Cons. Consumption Unit Price
(USD)/ Process Chemical
(USD/kg) (g/L) (kg) (USD/kg)
Process

0.30 2.40 NaOH (25%) 2.00 4 0.3

6.60 6.60 RC ESCUDO RC-1567 1.50 3 2.3
1.29 1.29
0.85 0.51 Neut. Dyeing Acid AF 0.30 0.6 0.85
CW
TOTAL 10.8 TOTAL

PLAN RC

Cons. Consumption Unit Price

Process Chemical
(g/L) (kg) (USD/kg)

NaOH (25%) 2.00 4 0.3

RC ESCUDO RC-1567 3.00 6 2.3

Neut. Dyeing Acid AF 0.30 0.6 0.85

CW
TOTAL
Liquid Automatic
Liquid Automatic

Liquid Automatic

Liquid Automatic
Powder Manual
Liquid Automatic
Liquid Automatic
 Cost
COST SAVING/
(USD)/ PROCESS
Process

2.96
6.90

9.86 56%

Cost
(USD)/
Process

1.20
6.90

0.51

8.61 -20%

Cost
(USD)/
Process

1.20
13.80

0.51

15.51 44%
CURRENT CLEANING WASH ZIPCO CLEANING WASH NAZOC

Cons. Consumption Unit Price

Supplier Chemical Supplier
(g/L) (kg) (IDR/kg)

Wash Bensin XH 1 15,500

Warna Prima Basunjaya

TOTAL 15,500
LEANING WASH NAZOCLEAN CA-111

Cons. Consumption Unit Price COST SAVING/

Chemical PROCESS
(g/L) (kg) (IDR/kg)

Nazoclean CA111 1 32,000

TOTAL 32,000 106%

REDUCING AGENT

Month Consume
(Kg) 0 Consume (Kg)
Apr 940 1200
May 950
Jun 1,010 1000
Jul 820
Aug 470 800
Sep 350
Oct 160 600

Nov 140
Dec 100 400

Jan 230
200

0
Apr May Jun Jul Aug Sep Oct Nov
 REDUCING AGENT

Month Consume (US

sume (Kg) $) 0 Consume
Apr 5,002.00 7000
May 5,752.90
6000
Jun 6,291.09
Jul 5,217.04 5000
Aug 3,086.21
Sep 2,117.48 4000
Oct 967.99
Nov 846.99 3000

Dec 604.99
2000
Jan 1,391.49
1000

0
ug Sep Oct Nov Dec 0 Apr May Jun Jul Aug
 0 Consume (US $)

Apr May Jun Jul Aug Sep Oct Nov Dec

CURRENT RC ZIPCO

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 2.00 4 0.30 1.20

RC ESCUDO RC-1567 1.00 2 2.30 4.60

Neut. Dyeing Acid AF 0.30 0.6 0.85 0.51

CW
TOTAL 6.31
CURRENT RC ZIPCO for FRLGR

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

NaOH (25%) 4.00 8 0.30 2.40

RC Reducing Agent 0.50 1 6.60 6.60
ESCUDO P-770 0.50 1 1.29 1.29
Neut. Dyeing Acid AF 0.30 0.6 0.85 0.51
CW
TOTAL 10.8
PLAN RC FOR FR-LGR

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

RC NaOH (25%) 2.00 4 0.3 1.20

ESCUDO RC-1567 1.50 3 2.3 6.90

Neut. Dyeing Acid AF 0.30 0.6 0.85 0.51

CW
TOTAL 8.61
PLAN RC FOR FR-LGR

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process

RC NaOH (25%) 2.00 4 0.3 1.20

ESCUDO RC-1567 3.00 6 2.3 13.80

Neut. Dyeing Acid AF 0.30 0.6 0.85 0.51

CW
TOTAL 15.51

PLAN RC FOR FR-LGR

Cost
Cons. Consumption Unit Price
Process Chemical (USD)/
(g/L) (kg) (USD/kg)
Process
RC NaOH (25%) 2.00 4 0.3 1.20
ESCUDO RC-1567 1.50 3 2.3 6.90

Neut. Dyeing Acid AF 0.30 0.6 0.85 0.51

CW
TOTAL 8.61
COST SAVING/
PROCESS

-20%

44%

-20%