PT TRIPUTRA AGRO PERSADA SS KOKOH T.

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

Company :PT. MEGA IKA KHANSA

TRIPUTRA AGRO PERSADA GROUP
Address : Desa Telaga Pulang Kec. Sembuluh,
Kab. Seruyan, Kalimantan Tengah
INDONESIA

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

Company Profile TAP GROUP

Established : April 1, 2005
Head Office : The East Tower, Floor. 23
Jl. Lingkar Mega Kuningan Kav E3.2 No. 1
South Jakarta Indonesia
Estate : Sumatera : PT. BBB
Kalteng : PT. GBSM, PT. MIK, PT. TAN,
PT. SKM, PT. FLTI
Kaltim : PT. MSL, PT. EBL, PT. KSD, PT. DLJ, PT. NPN,
PT. HPM, PT. SAWA, PT. KAM, PT. PTA
Kalbar : PT. KSA, PT. BHA, PT. SEP, PT. DAP, PT. PWA
Mill : 7 Mills with 60 ton/hour
Sumatera (PT. BBB), Kaltim (PT. EBL), (PT. MSL), (PT. DLJ)
Kalteng (GBSM), (PT. FLTI), Kalbar (PT. BHA)

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

Company Profile TAP Group Region Kalteng

KALIMANTAN TENGAH
1. PT. Gawi Bahandep Sawit Mekar
2. PT. Mega Ika Khansa
3. PT. Trieka Agro Nusantara
4. PT. First Lamandau Timber International
5. PT. Sukses Karya Mandiri

PT. MEGA IKA KHANSA

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

PRELIMINARY
Triputra Agro Persada Group is a group of companies engaged in oil palm plantations and CPO production. PT. Mega
Ika Khansa is a subsidiary company of Triputra Agro Persada Group. Statement of PT. Mega Ika Khansa about
environmentally-friendly based on Corporate Policy and Implementation on SOP we commit that ABSOLUTELY
NO OPENING OF LAND WITH BURNING.

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

Profile SS
Name : Kokoh Tri Handoko
Function : Assistant
Department : Research and Development
Joined TAP Group : April 1, 2015 MT Batch XXXIX
Idea Implementation : Maret Juni 2015

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

DESCRIPTION CPT
CIRCLE PATH

Fresh Fruit Bunch Collection Point

CPT is Weeds Spraying activity on Circle, Path and Fresh

Fruit Bunch Collection Point use herbicide that
recomended by Company

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

FLOW PROCESS OF CIRCLE, PATH and FRESH FRUIT BUNCH COLLECTION POINT (CPT)

1 2

Administration
Material mixing and picking

4 3

Application Morning Briefing

5 6

Reporting Daily Costing

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

ACTIVITY PLAN

Activity PIC March, 2015 April, 2015

P
Collecting Material
A

P
Mixing Mateial
A

P
Trial
A

Note Plan

Actual

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

BACKGROUND & SITUATION ANALYSIST

Mikania micrantha (M. Micrantha) generally grow predominantly in the area of oil palm immature (TBM) to be twisted /
covered the entire frond / palm canopy. Mikania also produce residues in the form of Phenol compounds and flavones. Easy
to breed through a stem and seeds. Seed viability of over 60%, while its power is growing cuttings can reach 95%.
Sembung Rambat (Mikania micrantha) is a weed that can reduce the growth and productivity of some crops
(Priwiratama, 2011).

Yield losses due to M. micrantha invasion example on plant oil palm (Elaeis guineensis) can reach 20%, the rubber tree
(Hevea brasiliensis) reaches 27-29% and in wheat (Triticum aestivum), which reached 28%. The nature of strong invasion of
weeds makes sembung unruly vines (Teoh et al., 1985 in Cock et al., 2000).

Sembung Rambat (Mikania micrantha) is a weed that can reduce the growth and productivity of some crops Palm Oil.
(Priwiratama, 2011).

Yield losses due to M. micrantha invasion example on plant oil palm (Elaeis guineensis) can reach 20%, the rubber tree
(Hevea brasiliensis) reaches 27-29% and in wheat (Triticum aestivum), which reached 28%. The nature of strong invasion of
weeds makes Sembung Rambat unruly vines (Teoh et al., 1985 in Cock et al., 2000).

Pasiflora poetida Ageratum Borreria alata

Mikania micrantha

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

THEME

Beside problem that stated before, others effect is :

1.Chemical material cost is high Rp. 14,473 / Hectare
Material Rp Total Rp Budget
Bulan
Month Prima Up Meta Prima Meta Prima Ha HK Ha/HK Rp/Ha %
Prima Up (Ltr) SBI Rp/Ha
(Ltr) (Kg) (Kg)
Desember'15 76,00 Rp 2.733.454 Rp 2.733.454 174,45 53 3,29 Rp 15.669 Rp 15.253 97%
Januari'16 282,75 12760,00 Rp 10.169.528 Rp 1.269.197 Rp 11.438.725 666,89 232,00 2,87 Rp 17.152 Rp 15.253 89%
Februari'16 402,30 20860,00 Rp 14.469.324 Rp 2.074.878 Rp 16.544.201 1143,11 328 3,49 Rp 14.473 Rp 15.253 105%
2. While doing spraying could have an impact in skin irritation and respiratory disorders
3. Environment issue
The Idea is to find substitute formulation which could replace Chemical material

Skin Irritation

Kill others
beneficial
Glifosat + Metilmetsulfuron plant

From that background problem, My Idea is :

To Make Natural Herbicide that is inexpensive and Environmentally Friendly
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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A
BEFORE IMPROVEMENT IMPACT ON QCDSME

BEFORE IMPROVEMENT IMPACT

Weeds die because of chemical herbicide QUALITY

Cost for CPT spraying for 3 Rotation using chemical herbicide
Rp. 111,324,678,- per year ( PT. MIK area ) COST
Stock for herbicide Glifosat & Metil Metsufuron is very low ,
because those material is very expensive DELIVERY
Could impact skin irritation SAFETY
Employee is worry to use that chemical herbicide MORAL
Not environmentally friendly ENVIRONMENT
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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

TARGET
Reducing cost of usage for Glifosat & Metil
Metsulfuron
SPECIFIC

To Reduce Glifosat & Metil Metsulfuron

usage Reducing cost of CPT spraying from Rp. 14,473 ,-
MEASURA to Rp. 7,000,-
BLE

Reducing 48% actual cost by conducting a trials

ACHIEVAB on natural materials
LE

48%
To Make substitute herbicide from natural
REASONA materials
BLE

March - April 2015

TIME
BOUND

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

IMPLEMENTATION PLANNING

When,
WHAT Where,
Why How Who Target
How
Problem Solution Much
Chemical The need to 1. Find a
material that improve Literature
caused on employees 2. Find natural
skin irritation health and materials
and not Beneficial 3. Mixing trials.
environment plant can 4. Spraying trials
friendly To make a stay alive 5. Check Result
6. Multiply March
formulation
materials April, Kokoh
replacing
at PT. MIK
Price for Herbicide Affordable
chemical prices and
material is ready on
high stock

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

IMPLEMENTATION PLANNING
IDEA : TO MAKE SUBSTITUTE HERBICIDE

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

IMPLEMENTATION PLANNING

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

IMPLEMENTATION PLANNING

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

IMPROVEMENT IMPLEMENTATION LIQUID MAKING PROCESS

Simi
Weighting Water : 5 L Hevea Leaf Blend Garlic Store
Water : 5 L Crushed the yeast Store the yeast
Ageratum Garlic

Store Store Hevea

Blender Ageratum Blender Leaf

Store crushed ingredients After 15 days filter it Master Solution

Mix all crushed and tightly closed in can
for 15 days
with fabric Liquid ready to
ingredients
use

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A Implementation of Spraying

Date 20 April, 2016
IMPROVEMENT IMPLEMENTATION
Time 07.00 WIB
Experiment I : Soft Weeds (Cyrtococcum oxyphyllum)
BEFORE SPRAYING 3 DAYS AFTER SPRAYING 7 DAYS AFTER 14 DAYS AFTER
100 cc/Knapsack

SPRAYING SPRAYING
Treatment I :

TRIAL

There are Empty Bunch The weeds partially start Dried Weeds, The stems are
application, not interfere turn to yellow still yellow
trial area (1x1 Meter).
Give the effect to Weeds
150 cc/Knapsack
Treatment II :

There are Jankos The weeds partially start Dried Weeds, The stems are
application, not interfere turn to yellow still yellow
trial area (1x1 Meter).
Give the effect to Weeds
200 cc/Knapsack
Treatment III :

There are Empty Bunch

application, not interfere
Almost all weed dried like All parts of the weeds dried
trial area (1x1 Meter).
burnt like burnt
Give the effect to Weeds

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

Experiment II: Wide Leaves Weeds (Mikania micrantha)

BEFORE 3 DAYS AFTER 7 DAYS AFTER 14 DAYS AFTER
SPRAYING SPRAYING SPRAYING SPRAYING
Treatment I

cc/Knap
: 100

Sack

On the Plot (1x1 Meter) with MS start give the effect to both The Weeds start turn to yellow The Weeds dried but not
Weeds Mikania micrantha of weeds equally to all weeds
and Pasiflora foetida
Treatment II :
150 cc/Knap
Sack

On the Plot ( 1x1 Meter) with Dried Weeds, The stems are
The weeds partially start turn
weeds Mikania micrantha
to yellow still yellow
and Pasiflora foetida
200 cc/Knap Sack
Treatment III :

MS start give the effect to both The weeds partially start turn All parts of the weeds dried like
of weeds to yellow burnt

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

EVALUATION OF RESULTS
ACHIEVEMENT AFTER IMPROVEMENT

Reducing Cost of Material Use

Glisofat & Metil Metsulfuron
18.000

16.000
14.473
14.000

12.000
DOWN
10.000 82 %
8.000 7000

6.000

4.000
2421
2.000
Aktual
0 Budget
February Maret Target Maret Actual

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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

EVALUATION OF RESULTS
Cost & Benefit Calculation
COST OF MAKING FOR
Making 10 Liter Master10 LITER MASTER
Solution
BEFORE IMPROVEMENT
SOLUTION (MS)
Before Improvement, Cost for material for CPT
To Make 10 Liters Master Solution, we need 23 minutes. spray as wide as 2,324.65 Ha (PT. MIK)
Cost of manpower collecting for basic ingredients
1 Ha = 0.375 L of Glifosat
Ageratum 5kg + Hevea Leaf 5kg Rp 13.205-,
Cost of HK/ 10 Liter Rp 13.463,- x 2,324.65 Ha = Rp 31.296.763,-
= 7 working hour x 60 minute = 420 minute 1 Ha = 0.018 Kg of Metil Metsulfuron
= Rp 92.440 / 420 minute = Rp 220 / minute Rp 1.790,- x 2,324.65 Ha = Rp 4.161.356,-
= Rp 220 x 23 minute = Rp 5.060,-
Transportation fee = Rp 1,650,107,-
Master Solution Ingredients :
Garlic : @100 grams Rp 5.000,- Cost of Material before SS (One Cycle) = Rp 37.108.226,-
Yeast : @1 pack Rp 7.000,- For 3 Cycles Cost of Material =
Rp 12.000,-
Total Cost for 10 Liter of Master Solution
Rp 111.324.678,-
= Rp 5.060,- + Rp13.205,- +Rp 12.000,- = Rp 30.265,-
Cost of 1 Liter Master Solution : Rp 3.026,- AFTER IMPROVEMENT
After Improvement, material MS for CPT spray for total
area 2,324.65 Ha
1 Ha = 0.8 L Master Solution
Rp 2.420,- x 2,324.65 Ha = Rp 5.625.653,
% Cost/Benefit Cost of Material after Kaizen (one cycle)
Rp 16.876.959,- = Rp 5.625.653,
Rp 94.447.719,- X 100 %
For 3 cycles Cost of Material spray is
Rp 16.876.959,-
17 % Saving Cost for Area PT . MIK =
Rp 94.447.719,-
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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A

EVALUATION
IMPACT COMPARISON OF QCDSME

BEFORE IMPROVEMENT IMPACT AFTER IMPROVEMENT

The Weed died because of chemical The Weed died because of organic /
herbicide QUALITY natural herbicide

Cost of spray on CPT for 3 rotation at Cost of spray on CPT for 3 rotation
PT. MIK = Rp 111.324.678,- PT. MIK = Rp 16.876.959,-
COST
Stock for Glifosat and Metil Metsufuron Material herbicide stock availability is
difficult to buy and the price is expensive DELIVERY good

Skin irritation No effect to human

SAFETY
Employee are worry to get in touch with Employee arent worry because Master
chemical herbicide Solution dont give any effect
MORAL
Not environmentally friendly Environmentally friendly
ENVIRONMENT
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 PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

STEP P D C A NEXT ACTIVITY

AGUSTUS SEPTEMBER OKTOBER NOVEMBER DESEMBER
EVALUATION No AKTIFITAS LUASAN
W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Plan
1 Spray di MIK Hamparan
Act
Plan
STANDARDIZATION 2 Spray di GBSM Demplot
Act
Plan
3 Spray di FLTI Demplot
Act
Plan
4 Spray di SKM Demplot
Act
Plan
5 Spray di TAN Demplot
Act
Plan
6 Evaluasi
Act
Plan
7 Standarisasi Lanjut
Act

PPKS RECOGNATION

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PT TRIPUTRA AGRO PERSADA SS KOKOH T.H

INTERNATIONAL QUALITY & PRODUCTIVITY CONVENTION 2016

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