A16. PKM Saungku - PT Pupuk Kujang

PKM SAUNGKU-PUPUK KUJANG CIKAMPEK
TEMU KARYA & PRODUKTIVITAS NASIONAL XXI

and
INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2017
COMPANY PROF ILE

COMPANY
Circle Name
PROFILE
: PKM Saung Ku
Organization : PT Pupuk Kujang Cikampek
Location : West Java - Indonesia
Project Title : Improve the productivity of local fruit by 20-30% with
environmentally friendly balanced fertilizing system
Opportunity : Economy value : IDR 14.624.053.294
Income
PT Pupuk Kujang Cikampek (PKC) is a subsidiaries of PT Pupuk
Indonesia (Persero), that is engaged in industry, trading and
services of fertilizer , petrochemical, agrochemical, agroindustry as
well as other chemical services. PKC is located in Jl. Jend. A.Yani
No.39 Cikampek, Kab.Karawang 41373. PKC has 2 urea plants 1A
and 1B with production capacity 1.140.000 tons/year, NPK
Blending Plant, Granul I and Granul II plant with production
capacity about 300.000 tons/year.
Recently PKC is developing retail products which is being
developed by Research Department as improvement business , it
is caused by economic global condition with the introduction of
MEA including agriculture field toward to free market.
THEME OF QUALITY IN 2017
“INCREASE THE PRODUCTIVITY OF LOCAL FRUIT BY 20-30%.”

FRAME WORK OF INNOVATION MEMBERSHIP
PLAN-DO-CHECK-ACTION 8 STEPS Facilitator
1. Determining the theme & the tittle
2. Determining the cause ofthe problem
3. Analyze the dominant cause
4. Planning the Improvement & target
5. Improvement Process
6. Examining Improvement Process
7. Standarization
8. Determining the next theme Arlyza E.W.
INNOVATION IDEA
To create a new idea of product , Research
Department has 2 ways , first it cooperation with
government research institution , university and
second from internal ideas of research
department itself ( it comes from management
disposition , improvement , literature , market
expantion , stake holder request etc ) . Both of
them refer to market needed that synergied with
government policy .
2015 2016 Encounter
Phase
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 Plan Actual
1 Determining the theme & the tittle 4 4
2 Determining the cause ofthe problem 3 2

P
3 Analyze the dominant cause 3 3
4 Planning the Improvement & target 6 8
D 5 Improvement Process 15 16
C 6 Evalua Examining Improvement Process tion 6 6
7 Standarditation 4 4
A
8 Determining the next theme 4 3
Plan Aktual 45 46
Page-1
and
STEP I. DEFINE THEME & GOAL SETTING
STEP I. DETERMINING THE THEME & THE TITTLE
P Period : 1st of January - 28th of February 2015
1.1 STATEMENT OF PROBLEM
1. Current Fertilizer Business Situation
a. The Indonesian government will remove the policy of fertilizer subsidy in 2018, this will affect the
continuity of PT. Pupuk Kujang business as a producer.
b. In the era of the Asian economic community, the domestic market has been flooded with fertilizer from
various domestic and foreign producers, so the competition is more complicated, especially for PT. Pupuk
Kujang.
2. Base on the current situation at above that they give some complication impact for PT. Pupuk
Kujang, as following:
a. PT Pupuk Kujang cannot compete with the competitor if still on subsidized fertilizer business only.
b. PT. Pupuk Kujang will be left behind and lost the market if it does not do business transformation by
developing superior fertilizer products for the horticultural sector is still a large market opportunity.
3. Opportunities for PT. Pupuk Kujang, as following:
a. PT. Pupuk Kujang have to transform his business by developing diversification of fertilizer product for
sector horticultural, because today in this sector that it horticultural productivity is still low, so the
Indonesian government must import horticulture to fulfill its domestic needs.
b. Farmers need new technologies and guidance in terms of cultivation that can improve the productivity
and quality of their crops.
c. And as new income for PT. Pupuk Kujang from sales of the new products.
1.2 ANALYSIS OF PROBLEM
Imported Fruit in Imported fruit in

Supermarket Modern Market
Source: http://www.fbbnipb.com/2015/05/kondisi-ekspor-dan-impor-buah- Productivity

nusantara.html of local fruit Imported fruit inTradisional
Figure 1.Indonesian Fruit Export&Import is still low Market
The main problem of the fruit production is the level of damage is quite high from the production in the
field (on farm) and post-harvest (off farm) .Level of damage on average reaches between 30-60%. The
below table depict the commodities of horticulture of fruit local goes to down. The average productivity is
minus 9 percent. Below table 1 is some commodity of fruit local in period 2014/2015.
No. Commodity Kg/tree/years Growth
2014 2015 (%)
1 Avocado 157,08 148,69 -5%

2 Star Fruit 125,37 105,16 -16% -9%
3 Durian 137,23 128,58 -6%
4 Orange 90,63 83,46 -8%
5 Pamelo 208,4 178,69 -14%
6 Banana 82,27 85,65 4%
7 Mango 110,32 112,2 2%
8 Mangosteen 90,76 76,47 -16%
9 Rambutan 82,31 70,22 -15%
TOTAL 1084,37 989,12 -9% Figure 2. Productivity of Local Fruit Production, 2014-2015
Table 1.Indonesian Fruit Growth -9%
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and
1.2.1 THEME SETTING
 Reference research results related to the productivity of local fruit as in the following table 2.
No Researcher Year Research Result Fertilizing
1 Nana Sutrisna and 2012 increase productivity by 20-50% anorganic fertilizer combined
Nandang Sunandang compared to only using ordinary with organic fertilizer
fertilizing system
2 Emma Trinurani and 2016 fertilizing with Bio fertilizer combine Bio fertilizer
Stefina Liana Sari with NPK able to increase yield by
32% in soybean
Base on research reference, the initial target for opportunity improvement to increase production of local
fruit is 20 until 32 %.
 Aspect of Fruit Production Before Improvement
Table 3. Quality aspect of existing local fruit production before improvement
QUALITY
EXISTING TARGET
ASPECT
Productivity of local fruit decerease about 9% in Productivity increases by Minimum 20 to
PRODUCTIVITY
2015 30 %.
Quality of soil and the yield will decrease because Farmers change to use balanced fertilizer
QUALITY
of using single fertilizer or anorganic fertilizer . from PKC’s products
Fertilizer cost incurred by farmers of IDR  Fertilizer cost incurred by farmer of IDR
25.000/plant/year (sampling of orange farmer in 20.000/plant/year( fertilization 3 times /
COST Garut , if using a single fertilizer and imported year) use balanced fertilizer.
fertilizer as additional fertilizer ).  The opportunity to increase revenue from
sales of non-urea product..
The use of subsidized fertilizer is limited to delivery Farmers use non PSO (public service
DELIVERY
because it is limited by the distribution area obligation) fertilizer
Single fertilizer is easy to melt so it is less safe for Balanced fertilizer is relatively safe . PKC
worker and excessive of urea spill can lead to has non- urea fertilizer that can be
SAFETY &
environmental damage. optimized to improve soil nutrient and fruit
ENVIROMENT
quality as well as safe for the environment
and human health.
Nutrient contain is still low because the fruit does Nutritional quality of fruit is good because
HEALTHY
not get the balanced nutrients . the plants get enough nutrients.
PT Pupuk kujang can not response rapidly in term PT Pupuk Kujang responses with
of Farmers complainting about how to increase the customer’s need and complaint rapidly and
MORALE productivity . give the solution with its products to
increase the productivity and the farmer
welfare.
 Conclusion:
Based on the initial target and existing of the local fruit production before improvement is still low and
decreased, and so our team sets the theme for this period is “ Increase productivity of local fruit by 20-
30%”.
1.3 SETTING OF TITLE
Standard quality of local fruit is presented on below tables. We distributed questionnaires to 35 internal and
external respondents (farmers) at some areas in west java , central java and east java . The below table show
the quality of local fruit before improving.
Table 4 : Visual Quality of Local Fruit
Texsture
Item Total
Avarage
Strength Firmness Softness Crispness Sukulen Juiciness Score
Standard 4 4 4 4 4 4 24 24
Currently 2 2 2 3 2 3 14 2,3
Gap 1 1 2 1 2 1 8 1,3
Page-3
and
Table 5 : Texture Quality of local fruit
Visual
Item
Size Shape Color Glossiness Defect Fineness Total Score Avarage
Standard 4 4 4 4 4 4 24 24
Currently 2 3 2 3 2 2 14 2,3
Gap 1 1 2 1 2 2 9 1,5
Note:
 Assesment with scale score system 1 to 5 :1= Very low; 2=Low; 3=Fair; 4=Good; 5=Very good
Shading boxes symbol = 4 to 5; 5 = 3 to<4; = 0 to<3
 Gap is opportunity for improving (increased or decreased)
Conclusion : Quality of local fruit is still low with score of 2,3
Base on the existing score, the PKM SAUNGKU set an initial target to improve quality of the local fruit is to
be 4 or 100% from 2.3. It is shown on figure 3a-b. While the initial target for improving the productivity of
local fruit horticulture yields is set by PKM SAUNGKU at 30% of the yield before the improvement base on
reference in previous table 2.
(Source: Observation in Semarang Sub-District, Garut for “Orange Keprok” in 2012).

Based on the initial target for the quality and productivity of the fruit local horticulture, the PKM’s SAUNGKU
establishes the title of innovation for this period is:
TITLE OF INNOVATION
“Improve the productivity of local fruit by 20-30% with balanced fertilizer system”
In achieving the target , PKM SAUNGKU sets the strategies as follows:
 Innovation of environmentally friendly fertilizer product development in a sustainable and competitive
manner.
 Use all resources are owned by company optimally both human resources , technology and brand .
 Synergy between Research, Demontration Plot (Demplot), Marketing, GP3K, PKBL, Government
agencies, Community Institution as well as farmers group.
Records of management input:
Menyetujui, Mengetahui,
Menyetujui, Diajukan Tim
Mengetahui,
Inovasi Diajukan Tim Ino
Menyetujui, Mengetahui, Diajukan Tim Inovasi
Approved by To known by Submitted by :
Arlyza
Arlyza Eka W.
Eka W. Arlyza
ArlyzaArlyza
Eka W. Eka
Eka W. W. SarwendahSarwendah
Arlyza Eka W.Puji Rahayu Sarwendah Puji R
Puji Rahayu
Research Manager
Manager Riset Facilitator
Fasiltator Ketua Tim
Ketua Tim GKM
Team
GKM
SAUNGKU-2
Leader
SAUNGKU-2
Ketua Tim GKM SAU
Manager
th Riset Fasiltator
Manager th Riset Fasiltator th
Date on : 27 of February 2015 Date on : 27 of February 2015 Date on : 27 of February 2015
Tanggal : 27 Februari 2015 Tanggal: 27 Februari 2015 Tanggal : 27 Februari 2015
Tanggal : 27 Februari 2015 Tanggal:
Tanggal : 27 Februari
27 Februari 2015 2015TanggalTanggal:
: 27 Februari
27 Februari
2015 2015 Tanggal : 27 Februari
STEP II. DETERMINING THE CAUSE OF THE PROBLEM
P II.
STEP ANALYSIS CAUSE Period:OF THEofPROBLEM
1st-30th March 2015
2.1. Causes Inventory
PKM SAUNGKU members do brainstorming, about cause of low productivity local fruit
Page-4
and
Table 6. Inventory Causes Of Productivity Of Local Fruits Is Still Low
No. Causes of Problem Stratifiaction
1 Plant can not absorb of NPK element Media
2 Soil microorganisms are inactive to break down organic matter Media
3 The degree of acidity of soil is high Media
4 Fertilization is inefficient and effective Material
5 The fertilizer is not absorbed perfectly by the plant Material
6 Fertilizer is lost by rain Material
7 Fertilizer is easy washed by water Material
8 Quality of seed is low Material
9 Soil fertility decrease Material
10 Absorbed nutrient capacity of soil reduce Material
11 Soil microorganisms decrease Material
12 Fertilization is not balanced by Bio fertlizer Material
13 Low cation exchange capacity Material
15 Fertilization is not balanced by organic fertilizer Material
16 The shape of Fertilizer is prill/powder Material
17 Fertilization only uses a single fertilizer Material
18 Plant do not get enough nutrients Methode
19 The cropping distance is not appropriate Methode
20 Fertilization does not fit the needs of plant nutrient Methode
21 Fertilization is not balanced Methode
22 Inappropiate fertilization interval Methode
23 Fertilization system is not economical Methode
24 Fertilization system is excessive Methode
25 Plant is poisoned Methode
26 Use of excessive pesticides Methode
27 Farmers prefer to use single fertilizer Man
28 Farmers are easier to get single fertilizer Man
29 Farmers do not know about availability of balanced fertilizer Man
30 Farmers do not use suitable fertilizer Man
31 Farmers do not know about fertilizer product for fruit Man
32 Farmers do not know negative impact of bodies water that grow on plant Man
33 Farmers do not know how to applicate effective and efficient fertilization Man
34 Pollution on bodies water Environment
35 Poisonous soil Environment
36 Excessive of cultivation Environment
37 Various biological of macro and micro of soil decrease Environment
2.1.1. The cause and effect diagram of low local fruit productivity based on result of brainstorming
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and
2.1.2. Causes Factor expected Dominant Based on Group Technique Nominal (NGT) Results
Table 7. Rating result NGT Causes Factor
Appraisal of Members
No. Root Cause Y D SP AF
Scores Ranks
1 Farmers do not know how to applicate effective and I
14 14 14 14 56
efficient fertilization
2 Fertilization is not balanced by organic fertilizer 13 13 11 13 50 II
3 The shape of fertilizer is prill/powder 12 12 13 11 48 III
4 Fertilization is not balanced by Bio fertlizer 10 10 12 12 44 IV
5 Fertilization only uses a single fertilizer 11 11 9 10 41 V
6 Excessive fertilizing dosage 9 8 8 9 34 VI
7 Farmers less of knowledge about balanced fertilizer 7 7 10 8 32 VII
8 Inappropiate Fertilization interval 8 9 7 7 31 VIII
9 Farmers do not know negative impact of bodies water that IX
6 6 6 6 24
grow on plant
10 Use of excessive pesticides 4 5 5 5 19 X
11 The cropping distance is not appropiate 3 4 4 3 14 XI
12 Farmers do not know about availability of balanced fertilizer 5 3 2 4 14 XII
13 Excessive of cultivation 2 1 3 1 7 XIII
14 Quality of seed is low 1 2 1 2 6 XIV
2.2. Conclusion
Based on the result of 14th of dominant caused factor with NGT methode , so factors that expected dominant
for low productivity of local fruit is 8 factors , namely:
1. Farmers do not know how to applicate effective and 5. Fertilization only uses a single fertilizer
efficient fertilization 6. Excessive fertilizing dosage
2. Fertilization is not balanced by organic fertilizer 7. Farmers less of knowledge about balanced
3. The shape of fertilizer is prill/powder fertilizer
4. Fertilization is not balanced by Bio fertlizer 8. Inappropiate Fertilization interval
STEP III. ANALYZE OF DOMINANT CAUSE

P III. DETERMINE OF
STEP DOMINANT
Periods: 1st – 30th ofCAUSE
April 2015
3.1. Observation of The Possibility Dominant Causes

Observation period : March to April 2015
Responsibility : Yogi
Member of observer : Sarwendah, Ahmad Fauzi, Drikarsa
Location of data observation : 20 Sample points of land horticulture
Table 8 . The Cause Factor Expected Dominant in 20 sample points of land horticulture in West Java.
No Root Causes factor Actual Qty Defect Cumm
Finding Finding ulative
1 Farmers do not 20 14,18 14,18
know how applicate As Pareto by 85,11%
effective and
efficient fertilization
2 Fertilization is not use non- 20 14,18 28,36
balanced by organic organic
fertilizer fertilizer
(Urea, ZA,
TSP)
3 Shape of fertilizer is 20 14,18 42,54
prill / powder
4 Fertilization is not use non- 20 14,18 56,72
balanced by bio bio fertilizer
fertilizer (Urea, ZA,
TSP)
5 Fertlization only use non- 20 14,18 70,9

uses a single balanced
fertilizer fertilizer
(Urea, ZA,
TSP)
6 Farmers less of 20 14,18 85,08
knowledge about
balanced fertilizer
7 Inappropiate Twice 16 11,35 96,43
fertilization interval Fertilization
average
every year
8 Excessive 5 3,57 100

fertilization dosage
Total 141 100
Page-6
and
3.2. Conclusion:
Base on the pareto of root cause on the picture above, there are six dominant factor that cause the
productivity and quality of local fruit is low, as follow:
1. Farmers do not know how to applicate effective and efficient fertilization
2. Fertilization is not balanced by organic fertilizer
3. Shape of Fertilizer is prill/powder
4. Fertilization is not balanced by Bio fertlizer
5. Fertilization only uses a single fertilizer
6. Farmers less of knowledge about balanced fertilizer
The sixth of dominant causes will be done improving at next step.
STEP IV. PLANNING THE IMPROVEMENT & TARGET

P IV.IMPROVEMENT
STEP Periods:PLAN
1st of May – 31th of August 2015
4.1. SOLUTION FOR IMPROVEMENT PLANT
Table 9. Selection of solutions to the dominant cause of low productivity of local fruit
Dominant Root
No Categories Impacts Solutions Decissions
Causes
1 Farmers do not Inappropiate Less understanding of 1. Provide training and Accepted
know how to fertilization nutrient conditions, so field farmers meeting
applicate effective methods farmers do fertilizer
and efficient based on experienced 2. Field farmers Accepted
fertilization (1) or follow the others. meeeting conducted
2 Farmers less of They do fertilizer at key farmers at the
knowledge about excessively, so central area in order to
balaced fertilizer (6) productivity is have a positive effect
disrupted. on other members.
3 Fertilization is not Use of 1. Soil health is 1. Create new balance Accepted
balanced by unbalanced damaged, so that fertilizer formulas that
organic fertilizer (2) fertilizer nutrients in the soil are environmentally
decrease, friendly, improve soil
biodiversity healthy and improve
decrease, it cause quality and yield.
4 Shape of Fertilizer low productivity. 2. Determination of Accepted
is prill/powder (3) fertilizer formula
5 Fertilization is not 2. Farmers applicate appropriate to plant
balanced by Bio fertilization with a needs and flexible and
fertlizer (4) single fertilizer general fertilizing
regardless of dose application for all
6 Fertilization only
and type, so it does types of locations.
uses single fertilizer
not fit the nutrients of
(5)
the plant.
4.2. ACTION PLAN

4.2.1. Use Of Unbalanced Fertilizer
Table 10. 5W+2H, Improvement Plan of Dominant Factor ‘Use of unbalanced fertilizer’
Dominant
causal factors 1. Fertilization is not balanced by organic fertilizer 3. Fertilzation is not balanced by Bio fertlizer
2. Shape of Fertilizer is prill/powder 4. Fertilization only uses single fertilizer
What Make fertilizer formula that can improve the productivity and quality of fruit and keep soil fertility
Why In order to the soil is maintained, the amount and useful biodiversity available and the effectiveness
of optimal NPK fertilizer application so that the productivity increases.
When 1st of June 2015 – 31th of January 2016
Who Compilator : PKM SAUNGKU, Implementer : PKM SAUNGKU, Demonstration plot (Demplot) team
(Research Department, Marketing Department) and Partner of PKC. PIC : Research Manager.
Where Internal & eksternal research farm (Multilocation test), Research laboratory, Demonstration plot
(demplot) area
How Step I
1.1. Make candidate formula of organic fertilizer, Bio fertlizer, and anorganic fertilizer
Page-7
and
1.2. Cooperate with research institute from goverment and university
1.3. Make prototype product and quality test.
1.4. Determine the location for the effectiveness test formula on horticulture
1.5. Do test effectiveness
1.6. Make packaging design, product release permit and mass production
1.7. Create branding and marketing strategies
1.8. Production Monitoring
1.9. Improvement and sustainable development
How Much 1.10. Target improvement plan
Target  Create 3 combinations of balanced fertilizer (anorganik, organic, and Bio fertlizer)
 Applied at research farm, and demplot locations at fruit horticultural area.
How Much Investment cost for product development in research scale is IDR 301.570.000,-
Investment Cost
4.2.2. Inappropiate Fertilization Method
Table 11. 5W+2H, Improvement Plan of Dominant Factor ‘Inappropiate method’
Causes
Dominant Farmers do not know how to applicate Farmers less of knowledge about balanced
effective and efficient fertilization fertilizer.
Factors
What 1. Lead mentoring to Local Fruits farmers

2. Applicate fertilization methods that fit the nutrient needs of local fruit crops.
Why Because farmers do not know about how to applicate fertilization
When 1st of June 2015 to 31th of December 2016
Who Quality compilers : PKM Saungku, Improvement executor : PKM SAUNGKU, Demontration Plot
(Demplot) Team (Research Dept , Marketing Dept) , PIC : Research Dept.
Where Internal & external experiment garden (effectiveness test site), Research PKC laboratory, Location of
demonstration plot (Horticulture production center).
How Steps of determine the type of fertilization
1.1. Soil and leaf nutrient analysis.
1.2. Determine fertilization that fit to 6 precise and environmentally friendly (secret formula)
1.3. Implement fertilization:
1.3.1. Selection of plant commodities to be increased productivity.
1.3.2. Selection of fertilizer & appropriate fertilization method .
1.3.3. Record the fertilization process that includes location, date, dose, type of fertilizer,
fertilization method, and PIC of fertilization.
1.4. Provide or create a fertilizer process control device
1.5. Schedule from August 2015 to December 2016 ( Schedule attached ).
Steps of fertilization application assistance
1.1. Conduct survey of demplot location.
1.2. Conduct field school activities to provide product socialization materials.
1.3. Perform basic fertilization activities.
1.4. Conducting the implementation of planting prime.
1.5. Perform fertilization activities of stages 1, 2 and 3.
1.6. Observe 2 weeks before harvest.
1.7. Implementation of the harvest
1.8. Report on mentoring activities
1.9. Ongoing monitoring and improvement.
How Much Maintenance Plan Target
Target  Understanding of farmers in fertilization and planting increases.
 Production of local fruits increase by 25 to 30 %
 Understanding farmers in fertilizing and planting increases.
 Farmers do a good and proper fertilization process. (SECRET METHOD)
 Production of local fruit increase by 20 to 30%.
How Much Cost Investment cost for effectiveness test is IDR 51.710.000,-
4.3. Risk and Prevention
4.3.1 Risk Identification
Risks that may occur to improve the cause problem of low local fruit productivity are as follows:
1. Risk of investment cost
2. Risk of failure in the research
Page-8
and
3. Risk of failure of the product
4. Risk of market and consument
4.3.2 Risk Mitigation
Mitigation against the four possible risks to improve the cause problem of low local fruit productivity is as
follows:
1. Investment cost mitigation is evaluated the economic value of the investment to the benefits to be gained.
2. Mitigation failure of the research, feasibility study is required before carrying out the improvement plan.
3. Mitigation failure of product , comprehensive studies are required before mass production with demplot.
4. Mitigation of markets and consument, conduct base on research and study of the market or consument
needs and direction of global business policy.
4.4. Economics Value
 Invesment : IDR 301,570,000 in Reasearch Scale
 Sales : IDR 15,043,801,000 in one year
 Ecomomize Value : IDR 14,742,231,000
4.5. Management Approval
Manager’s comment:
Menyetujui, Menyetujui,
Mengetahui, Mengetahui,
Diajukan Tim Inovasi Diajukan Tim Ino
Arlyza Eka W.
Arlyza Eka W. Arlyza Eka
ArlyzaW.
EkaEka
Arlyza W. W. Sarwendah Puji Rahayu
Sarwendah
Research
Manager Manager
Riset
Manager Riset Fasiltator
Manager Facilitator
Fasiltator
Riset Ketua Tim GKM Leader
Timof
SAUNGKU-2
Ketua
Fasiltator PKMSAUNGKU-2
GKM SAUNGKU Ketua Tim GKM SAU
th th th
Date on :27 August 2015
Tanggal : 27 Februari 2015
Date on : 27
Tanggal:
27 Februari
August 2015
2015
Date on
Tanggal :
: 27
27
August2015
Februari
2015
Tanggal : 27 Februari 2015 Tanggal: 27 Februari
Tanggal 2015
: 27 Februari 2015TanggalTanggal:
: 27 Februari 2015
27 Februari 2015 Tanggal : 27 Februari
of product development and d well so that the r
repared cordance with th
STEP V. IMPROVEMENT PROCESS
D V. IMPLEMENTING
STEP Period: 1st of June 2015 – 30th of April 2016
IMPROVEMENT
5.1. Realization of Improvement Plan
NO Use of unbalanced fertilizer
1 IMPROVEMENT
1. Make candidate formula of organic fertilizer, bio fertilizer, and anorganic fertilizer
Type Explaination Result
Biofertilizer Soil microorganism enrichment (Phospate
New
solvent, Nitrogen fixation and Product
Phytohormon Produce)
Chemical Slow release, anti leaching fertilizer and New
Fertilizer Product
appropiate for fruits
Organic Soil ammeliora (soil conditioner)
New
Product
2. Cooperate with research institute from goverment and university

3. Make prototype product and quality test.
4. Determine the location for the effectiveness test formula on horticulture
5. Do test effectiveness
6. Make packaging design, product release permit, and mass production
7. Create branding and marketing strategies
8. Production Monitoring
9. Improvement and sustainable development
INFORMATION :
Improvement activity time : 1st of June 2015- 30th of April 2016
Improvement executive : Compiler : PKM SAUNGKU, Implementer : PKM SAUNGKU, Demplot team
( Research Dept, Marketing Dept ) and Partner of PKC. PIC : Research Manager .
Improvement place : Internal & eksternal research farm (Multilocation test), Research laboratory,
Demonstration plot (demplot) area
Page-9
and
NO Inappropiate Fertilization Methods
1 IMPROVEMENT
Steps of determine the type of fertilization

1.1.Soil and leaf nutrient analysis.
1.2.Determine fertilization that fit to 6 precise and environmentally friendly (secret formula)
1.3.Implement fertilization:
1.4.Selection of plant commodities to be increased productivity.
1.5.Selection of fertilizer & appropriate fertilization method .
1.6.Record the fertilization process that includes location, date, dose, type of fertilizer, fertilization method, and
PIC of fertilization.
1.7.Provide or create a fertilizer process control device
1.8. Schedule from 1st of June 2015 to 30th of April 2016 ( Schedule attached ).
Steps of fertilization application assistance

1.1. Conduct survey of demplot location.
1.2. Conduct field school activities to provide product socialization materials.
1.3. Perform basic fertilization activities.
1.4. Conducting the implementation of planting prime.
1.5. Perform fertilization activities of stages 1, 2 and 3.
1.6. Observe 2 weeks before harvest.
1.7. Implementation of the harvest
1.8. Report on mentoring activities
1.9. Ongoing monitoring and improvement.
IMPROVEMENT RESULT
PREPARATION
Sampling Survey Location of demplot Soil Nutrient Content Test
Analisaunsur hara Analisaunsur hara

lahan/tanahuntukmenentukandosispupuk yang lahan/tanahuntukmenentukandosispupuk
diperlukandlmpemupukanperdana yang diperlukandlmpemupukanperdana
APPLICATION
1.Using Jeranti , Bion Up and Ex-Cow
First step fertilization use Ex-Cow, Bion-Up & Jeranti Fertilizers
Page-10
and
2.Monitoring for horticultural growth
Before
Before After
Before
Awal visual
danteksturd
First step fertilization (Growth of Awal visual
Second
Awal visual Step Fertilization
visual
Awal Thirds Stepr
aunand leaves) danteksturd
shoots danteksturd
(Growth of Fruits)
danteksturd fertilzation after
aun aun
aun harvest
3.Periodicaly Maintenance
Pemupukan 1 by Jeranti , Bion-Up and Pemupukan
Ex-Cow 2 Pemupukan 3
(Pantauperkembangandaun& (Pantauperkembanganbuah) (Setelahpanen)
ranting) Leaves,
Leaves,shoot
s,& fruits no shoots &
health fruits health
& lush
Using for maintenance before maintenance after maintenance

tHorticulture Farming
4.Report on mentoring activities
Monitoring for Quality Improving

Harvest results In Garut
INFORMATION :
Improvement activity time : 1st of June 2015 to 30th of April 2016
Improvement executive : Compiler : PKM SAUNGKU, Implementer : PKM SAUNGKU, Demplot team
( Research Dept, Marketing Dept ) and Partner of PKC. PIC : Research Manager .
Improvement place : Internal & eksternal research farm (Multilocation test), Research laboratory,
Demonstration plot (demplot) area
STEP VI . EVALUATE IMPROVING RESULT
Page-11
and
STEP VI . EXAMINING IMPROVEMENT PROCESS
C Period: 1st of April – 30th of June 2016
6.1. Evaluate the Result of The Improvement

6.1.1. Observation Harvest Result
Base on demplot location at some areas plantation for horticulture which be monitored by PKM
SAUNGKU, It can be presented on below tables for their quality and productivity.
 Quality
Tabel 10 and 11 . Quality ( visual & texture of local fruit after improving )
VISUAL
Items
Size Shape Colour Glossiness Defect Beauty Scores Rate
Standard 4 4 4 4 4 4 24 4
Improvement 4 4 3 4 4 4 23 3.83
Gap 0 0 1 0 0 0 1 1
TEXTURE
Items
Strength Hardness Softness Crispness Succulents Juiciness Scores Rate
Standard 4 4 4 4 4 4 24 4
Improvement 4 4 4 4 3 3 22 3.7
Gap 1 1 2 1 2 1 8 1.3
 Productivity
Tabel .12 show the productivity of horticulture yields at some demplot location in Java Island
No District Sub-district Village Comodity Unit Harvesting Value Percentage
(%)
Before After Increas
ing
2 Garut Wanaraja Sukamenak Tomato kg/plant 4,3 2,5 1,8 41,86
3 Garut Karangpawitan Cibolerang Tomato kg/ plant 4,5 2,5 2 44,44
4 Bojonegoro Trucuk Padang Guava ton/ha 5,2 3,2 2 38,46
7 Karanganyar Jumantono Sambirejo Longan kg/ plant 50 35 15 30,00
8 Karanganyar Jumantono Sambirejo Guava kg/ plant 25 15 10 40,00
9 Garut Sukawening Pasanggrahan Corn ton/ha 9,1 6,1 3 32,97
10 Subang Cijambe Cirangkong Pineapple ton/ha 4 2,6 1,4 35,00
11 Bojonegoro Kalitidu Mojo Star Fruit kg/ plant 20 15 5 25,00
Cummulative 35,97
6.1.2. Comparison of Targets
 Comparison for Quality of Horticulture Before, Target And After Improvement
100% 90.00% 100% 86.00%
4,00 3,83 4,00 3,77

2.3 2.3
Before Target After Before Target After
Comparison for Visual Quality (Score) Comparison for TextureQuality (Score)
 Comparison for Productivity of Horticulture Before, Target And After Improvement

130,09%  Conclusion:
100% The quality and productivity of the local fruit
have been improved those dominants factor
be increased, as follow:
1. The visual quality increased from 2.3 to
10,00 12,50 13,09 3.83 (90%) and the texture quality
increased from 2.3 to 3.77(86%).
Before Target After 2. The productivity for the yields increased
from 10.00 to 13.09 (130.09%) tons.
Comparison for productivity (Tons)
Page-12
and
6.2. Achievement Of Improvement base on Quality Aspects
Table.13: Achievment of Improvement base on Quality Aspect
Quality
Aspect Improvement Target Result
Increase productivity mininimum 20-30 %. Productivity has increased about 35.97%, it has
PRODUCTIVITY exceed from the target
Farmers used balanced fertilizer Farmers use Jeranti , Bion-Up and Ex-Cow
QUALITY
 Fertilizer cost IDR. 20.000/plant/year (3  Fertilizer cost IDR. 20.000/plant/year (3 times per
times per year) use balanced fertilizer. year) use Jeranti , Bion-Up and Ex-Cow fertilizer.
COST
 Chance to increased income from the  Potential revenue for PT PUPUK KUJANG by
non- urea products IDR 14,742,231,000.
Delivery of products is easy so that Farmers has easy to access product fertilizer,
DELIVERY fertilizer is available every where. because they cooperate with Pupuk Kujang to direct
access Jeranti , Bion-Up and Ex-Cow fertilizer .
Pupuk Kujang has concerned to Soil nutrient has available and maintained with use
SAFETY & maintaince soil biodiversity by making and Jeranti , Bion-Up and Ex-Cow fertilizer.
ENVIROMENT providing fertilizer which keep the fertility
and healthy of soil.
HEALTHY Plant nutrition is fulfiled so that the quality Quality score has increased from 2.3 to 3.8
of fruit increase
PT Pupuk Kujang responds to customer PT Pupuk Kujang has provide fertilizer product that
needs and complaints quickly and can increase the productivity average of 35.97% and
MORALE
innovatively with solutions to provide also the income of farmers. Farmer welfare
product that can improve the productivity of increased.
horticulture
6.3. Impacting and Mitigation

6.3.1. Impact
 The impact of success improvement resulting underserves demand.
 Cost occured during improvement for scale up production.
 Investing machine to produce product
6.3.2. Mitigation and prevention

 Reinvestment to increase production capacity as well as to coordinate comprehensively and
synergies ranging from forecasting, planning, realization and supervision.
 The cost occured have been budgeted in the investment of fertilizer product developers
 Coordinate among business unit function to achieve the target together by synergizing the vision,
mission, and target .
6.4. Benefit Analysis
6.4.1. Tangible Benefit:
 As a new revenue source for PT PUPUK KUJANG from retail products ( JERANTI , EXCOW and
Bion-Up ) by 100%.
 As a new value for farmers to increase efficiency in fertilizing application and improve productivity by
35,97%.
6.4.2. Intangible Benefit
 Preserve the environment and maintain the balance of soil fertility .
 Reduce pollution caused by non-environmentally friendly fertilization.
 Increase company branding and maintain the company’s sustainability .
 Increase company value in the form of concern for global business change and improve the
competitiveness of companies in the commodity market .
 Assist community nutrition improvement program by building sustainable environmentally friendly
products.
Page-13
and
6.4.3. Benefit for PKM SAUNGKU team
- Provide benefits to member of team to have passion for owning and performing innovative and creative
idea in their workplace .
- Increase communication skill each employees because improvement activity need good communication .
- To be good and positif benchmark for other team or other employee and give added value to motivate the
other .
- As one component of Key Performance Indicator ( KPI ) assessment or task force.
STEP VII . STANDARDIZATION

C VII . STANDARDIZATION
STEP Period: 1st of July – 31th of August 2016
7.1. Standard Procedure

1. Use Of Unbalanced Fertilizer
1.1. Propose / find candidate for environmentally friendly fertilizer formula .
1.2. Do research by cooperating with research institute from government and university.
1.3. Specify location for test of effectiveness of environmentally friendly fertilizer formula.
1.4. Do test effectiveness of environmentally friendly fertilizer ( Biological , organic and anorganic ).
1.5. Monitor of environmentally friendly fertilizer production.
1.6. Do improvement and derivate of environmentally friendly fertilizer product sustainably.
2. Inappropiate Fertilization Method
1.1. Conduct survey of premarketing location ( Demplot ).
1.2. Analyse soil and leaf nutrients
1.3. Determine the required dose of fertilizer and the timing of proper fertilization
1.4. Do “Farmer meeting” activity to socialize the product .
1.5. Do basic fertilization activity.
1.6. Do first planting activity.
1.7. Do activity of fertilization phase 1,2 and 3.
1.8. Do observation 2 weeks before harvest.
1.9. Do harvest.
1.10. Report on mentoring activity.
1.11. Monitor and control of improvement sustainably.
1.12. Do fertilization:
1.12.1. Selection of fertilization tools that have been calibrated eg sprayer for leaf nutrient fertilization .
1.12.2. Fertilizer available when needed
1.12.3. Do the process of storage of fertilizer, in-out of fertilizer ( fertilizer is stored in original packaging ,
label still attached to the packaging , dry and clean place, separated from seeds and pesticides )
1.12.4. Perform a recording of fertilization process which includes the location , date , dose , type ,the
way of fertilizing and the person performs fertilizing .
1.13. Provides / creates a fertilizer process control device
7.2. Standard Process
7.2.1. Process of developing of balanced fertilizer (Attached)
7.2.2. Process of effectif and effecient fertilization method and mentoring (demplot) (Attached)
7.3. Implementation Chart

7.3.1. Environmentally Friendly Fertilizer Development
Research and Development Stages Product Formulation & Test Production on Project Scale
Page-14
and
7.3.2. Effective and ooptimal fertilization method and mentoring
7.4. Standard of Result
7.5. Management Approval
ork Menyetujui, Mengetahui,

Menyetujui, Diajukan Tim
Mengetahui,
Inovasi Diajukan Tim Ino
Arlyza
Arlyza Eka W.
Eka W. Arlyza
ArlyzaArlyza
Eka W. Eka
Eka W. W. SarwendahSarwendah
Puji Rahayu
Research
Manager Manager
Riset Facilitator
Fasiltator Leader
Ketua
Ketua Tim GKM
Timof PKMSAUNGKU-2
GKM
SAUNGKU-2
SAUNGKU Ketua Tim GKM SAU
Manager Riset
th Fasiltator
Manager Riset
th Fasiltator
Date on :26 August 2016 Date on : 26 August 2016 Date on : 26th August 2016
Tanggal : 27 Februari 2015 Tanggal: 27 Februari 2015 Tanggal : 27 Februari 2015
Tanggal : 27 Februari 2015 Tanggal:
27 Februari 2015 2015TanggalTanggal:
: 27 Februari
27 Februari
2015 2015 Tanggal : 27 Februari
STEP VIII . DETERMINING THE NEXT THEME
A VIII .
STEP DETERMINE
Period: 1st NEXT THEME
of September – 31th of October 2016
8.1. Determine next theme

8.1.1. Prelimery of problem
“PKM SAUNGKU” surveyed farmers about the problems faced in agriculture , from the data we inventoried
and presented them in a pareto diagram below
Page-15
and
Based on pareto and risk assessment analysis, the main problem is about availability of NPKfertilizer for
annual fruit , so ” PKM SAUNGKU ” determines theme for next project is about :
“Providing availability of NPK fertilizer for annual fruit “
8.1.2. Analysis based on risk assessment

Possibility Impact Value
No Problem
(P) (I) (PXI)
1 Economic value of seasonal fruits is low 2 2 4
2 Demand of seasonal fruit 2 1 2
3 Availability of NPK fertilizer for seasonal fruit 3 3 9
Description of scala : 1=Low, 2=Medium,3=High, 4=Very high
8.1.3. Determine the tittle

The reason for tiile selection :
1. Farmers need balanced NPK fertilizer which is complete and balance for seasonal fruit such as
pineapple , cucumber and water melon etc Object formulation test is cucumber because it has high
economic value and demand from community increase .
2. Farmers do not need to mix single fertizer by themself because it does not appropiate as doses and type
to what the seasonal fruit need so it gives the negative impact to plant itself and soil .
3. Give potential revenue for PT PUPUK KUJANG
So “PKM SAUNGKU “ determines title for next project is about :
“PROVIDING AVAILABILITY OF BALANCED NPK FERTILIZER FOR ANNUAL FRUITS”
8.2. Management approval :

Management’s Comment: “ Please develop some products variance by combine ex-cow
with bion
u
Menyetujui, Mengetahui,
Menyetujui, Diajukan Tim Inovasi
Mengetahui, Diajukan Tim Ino
Approved by
Menyetujui,
To known by
Mengetahui,
Submitted by :
Diajukan Tim Inovasi
Arlyza Eka W. Arlyza Eka W.

Arlyza Arlyza Eka W. Sarwendah Puji R
Arlyza Eka W. Arlyza Eka W. Eka W. SarwendahSarwendah
Puji RahayuPuji Rahayu
Manager Riset Fasiltator Ketua Tim GKM SAU
Research Manager
Manager
Manager Riset Riset Facilitator
Fasiltator
Fasiltator Ketua Tim GKM Leader of PKM SAUNGKU
Ketua Tim GKM SAUNGKU-2
SAUNGKU-2
th Tanggal : 27 27thFebruari
Februari 2015 Tanggal: 27 Februari 2015 2015 Tanggal : 27 Februari
Date on: 27 October 2016
Tanggal : 27 Februari 2015 Date on : 27 October 2016
Tanggal:
Tanggal: 27 Februari 2015
2015 Date onl : 27th October 2016
Page-16

A16. PKM Saungku - PT Pupuk Kujang

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PKM SAUNGKU-PUPUK KUJANG CIKAMPEK

TEMU KARYA & PRODUKTIVITAS NASIONAL XXI

COMPANY PROF ILE

“INCREASE THE PRODUCTIVITY OF LOCAL FRUIT BY 20-30%.”

2 Determining the cause ofthe problem 3 2

4 Planning the Improvement & target 6 8

C 6 Evalua Examining Improvement Process tion 6 6

Imported Fruit in Imported fruit in

Source: http://www.fbbnipb.com/2015/05/kondisi-ekspor-dan-impor-buah- Productivity

1 Avocado 157,08 148,69 -5%

Table 1.Indonesian Fruit Growth -9%

(Source: Observation in Semarang Sub-District, Garut for “Orange Keprok” in 2012).

STEP III. ANALYZE OF DOMINANT CAUSE

3.1. Observation of The Possibility Dominant Causes

5 Fertlization only use non- 20 14,18 70,9

8 Excessive 5 3,57 100

STEP IV. PLANNING THE IMPROVEMENT & TARGET

4.2. ACTION PLAN

2. Shape of Fertilizer is prill/powder 4. Fertilization only uses single fertilizer

What 1. Lead mentoring to Local Fruits farmers

2. Cooperate with research institute from goverment and university

Steps of determine the type of fertilization

Steps of fertilization application assistance

Sampling Survey Location of demplot Soil Nutrient Content Test

Analisaunsur hara Analisaunsur hara

First step fertilization use Ex-Cow, Bion-Up & Jeranti Fertilizers

Using for maintenance before maintenance after maintenance

Monitoring for Quality Improving

STEP VI . EVALUATE IMPROVING RESULT

6.1. Evaluate the Result of The Improvement

100% 90.00% 100% 86.00%

4,00 3,83 4,00 3,77

 Comparison for Productivity of Horticulture Before, Target And After Improvement

6.3. Impacting and Mitigation

6.3.2. Mitigation and prevention

STEP VII . STANDARDIZATION

7.1. Standard Procedure

7.3. Implementation Chart

7.4. Standard of Result

7.5. Management Approval

ork Menyetujui, Mengetahui,

8.1. Determine next theme

8.1.2. Analysis based on risk assessment

8.1.3. Determine the tittle

“PROVIDING AVAILABILITY OF BALANCED NPK FERTILIZER FOR ANNUAL FRUITS”

8.2. Management approval :

Arlyza Eka W. Arlyza Eka W.

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