GROUP 1 NEDP BATCH 2

Ajeng Ghina F Imam Rafif H

Elsa Qorirotul AS Liza Mulyadiana

Rahmat Setiawan R
 PPC

CUSTOMER MATERIAL & PARTS

MARKETING PURCHASING

DESIGN WAREHOUSING

PRODUCTION
MANUFACTURING

PRODUCT
 Method
Man
Machine
Material
Money 5
M

Supplier Resouurces

Input Process Output Costumer

Plan
Taget Goals
 Establish one SC delivering User needs based on Spec Pattern

Integration with each partner

Supply Chain (SC)
Strict observance of delivery date

Supplier Plant DB/Dealer User

-Ensure -Reduce shipping Trust in delivery date -Reduce delivery L/T

production L/T - Supplying with proper
-Reduce inventory -Reduce inventory spec
DB Support - Reduce inventory at DB

Sale up, Share up

Concentrate the capital to
strengthen product support
 Funds
Supplier Customer
Information
Paying Information Processing Invoicing
Material Processing

Planning Order
Material & Management
Ordering Control

Receiving Manufacturing Distribution Delivery

 HANSEI

Sales and
Forecast
Production
Coordination
Operation

Material
Planning
Engineering PPC (PO&PDO)
Data Control

Inventory
Production Performance
Performance & Analysis
& Analysis
Man Power
Overtime
Management
(MPOT)
 Foundry Production

Foundry Engineering

SECTION
Product Planing Control
 MELTING
MOLDING
POURING

SHAKE OUT

1 2 3 4

8 7 6 5

DEGATING
SURFACE
HEAT CLEANING
FINISHING & TREATMENT
MACHINING
 MELTING PROCESS

Adjustment
Refining
Chemical
Composition

Metal Smelting Pouring to

Ladle
 ELECTRIC ARC
FURNACE

INDUCTION
FURNACE
MODERN
FURNACE TYPE

CUPOLAS

REVERBERATORY
 MOLDING
PLASTER CASTING

SAND CASTING V-PROCESS

LOST FOAM
DIE CASTING
CASTING

INVESTMENT
BILLET CASTING
CASTING
MOLDING METHOD
 The hardening of
sand mold made TYPE OF SAND
in the open air MOLDING

The process of Harden the sand

MANUAL SHELL
sand molding: with the aid of
MOLDING MOLDING
1. Pattern during process
Making
2. Molding Box &
Material
3. Installation
Chills
4. Installation
Core
 DEGATING

Oxy-Fuel Cutting
Cutting process with LNG
Tools Of
Degating

Gouging Torch
Sublimate using electrode
 HEAT TREATMENT

Normalising Cooling process with normal air

Quenching Sudden cooling with water or oil

Cooling process with holding on

Tempering certain temperature
FINISHING ACTIVITIES
 FLOW PROCESS KI

Supplier

Foundry

Fabrikasi Assembly Storage

IQT

Delivery

Hydraulic
 FABRICATION COMPONENT

Medium Excavator Big Excavator (PC 1250 & PC

(PC130,PC200,PC300,PC400) 2000)
Boom,Revo Frame Track Frame Revo Frame, Center Frame
 FABRICATION COMPONENT

Motor Grader
(GD511A):
•Front Axle
•Main Frame
•Body Scarifier
•Rear Frame
Bulldozer( D68, D85) •Tandem Case
Main Frame,Track Frame, •Drawbar
C-Frame
FABRICATION COMPONENT

Dump Truck (HD465,HD785): Rear Support

Main Frame

Export Component:
• Vertikal member RH/LH, Rear Cross
• RH/LH, Hoist Cross, Side Member
RH/LH (HD465, HD785)
• Rear Support (HD465)
• Boom (PC200)
• Arm (PC200)
 N
SAW G
Tack Self Ins p
MCS Welding Cek Check
Finishing Machining

RAW
N
N G
N G
G

Painting Self FC & Painting Shot

Self Self
Top Coat Cek Seat Primer Blast
Cek Cek

N
MCS G
Material Welding Assembling

Macchining Washing

Packing Testing

Warehouse Painting
Tool cuts and cold works for a
tube for mirror surface finish,
as required Hydraulic Cylinder
specification.
 Friction Welding

 Semi Automatic Welding

PRODUCT OF HYDRAULIC PLANT
IN KOMATSU INDONESIA
 BENEFITS (INDEX)

120

100

80

60 New
Reman
40

20

0
Price Quality Warranty
 Engine
Alternator
Transmission

Starter
Power
Module

Suspension P. Pump
Product Range
Motor

Cylinder Final
Axle
Drive
 ADJUSTMENT

Core Inspection Diss-Assy Washing Inspection

REPAIR

Warehouse Inspection Selvage

New Parts

Sub Assy Main Assy Dyno Testing

Painting

MANUFACTURING
RECEIVING INSPECTION PROCESS

Incoming Core

Visual Checking
(Core Condition)

Checking missing and damage part

Inspection Result +
Photograph
Next Process

Dis-Assembly
Process
DYNO TESTING

Komatsu Indonesia utilizing two

units engine Dynamometer with
capacity 2000HP and 800HP.

All of Engine Reman Products

produced by KI are tested one
this Dynamometer.
 A BIG LINE
S PC1250, HD465,
S HD785, GD511
E
MEDIUM LINE M
D85, D68, PC130,
PC160,PC195, PC200, PC300, B
PC400
L
Y BAYS
L
I PC2000
N
E
 CUSTOMER
SALES
ORDER
MCS COST CONTROL
CONFIRMATION
STORAGE & DELIVERY

SALES PPC
INSPECTION MASS PRODUCTION
PLANNING

MASS PURCHASING PPC

PRODUCTION MATERIAL
ORDERING
WAREHOUSE INSPECTION
MATERIAL RECEIVE
&
SUPPLY
 BENCH
ATTACHME FINAL MAINTENA
SUB LINE MAIN LINE INSPECTIO
NT CHECK NCE
N

NG OK
RECEIVING
DELIVERY CARGO CONFIRMAT REPAIR SHIPPING TOUCH UP
INSPPECTIO
NOTE READY ION SHIPPING INSPECTION MARKING
N REPORT

NG OK
ASIA DEVELOPMENT CENTER

Product Planning
& Development

Product
ADC Maintenance

Test & Tech

Admin
 Start
A

Market Research Design Output

Process Drawing
Assembly Drawing
Engineer BOM
Demand
Confirmatio
n
Trial Production
Fabrication
Survey Assembly
Purchase
Design Proposal Finish
Concept
Design Field Test

Cost+Profit Planning

No Factory Test
Managemen
t Approval Record
Yes Mass
No Production
Detail Design Record Release
Strength Analysis Approval
System Design Yes
Mechanism Design A
Planning Drawing Market Research
 Customer
request &
feedback

Field Test 3D Design

Trial
FEM
Production &
Analysis
Stress Test

47
TEST BUILDING

Test Building Established in 2013 to

support Technical Center
increasing needs for test inline
with increase demand for new
development product and/or
product’s improvement

Test Equipment
 NECRA1200 -> 6 Channel (1 Unit)
 Deicy DR600 -> 64 Channel (2
Unit)
 Pressure Measurement -> 7
Channel
 Temperature -> 12 Channel
 Receiving Process

Local Purchase
Production Inhouse Part
Import Purchase

Storage Process
WAREHOUSE ACTIVITY
FIFO When receiving goods employees
(FIRST IN FIRST OUT) will attach colour
Grouping of goods that have been
Storage by
Categories confirmed by QA based on
material properties
Cycle Counting Checking the goods periodically

Prepare & Supply

Production Order
Mid Term Production
(PDO)
 Raw Material

Semi Finish Material

Local
Import Finish Goods

Assembling Process Fabrication Process

Product Product

Finish Goods Inhouse Part

Sales
(Machine)
Finish Goods Sales
(Component) Component
 Kitting Small Process
Red Box Dump Truck & Motor Grader
Using
Blue Box Excavator Trolley
Supply For Production
Yellow Box Bulldozer

Kitting Medium Process

Main Line

Big Component
Direct Supply
 •Magnetic Test
Inspection
•Tensile Test •Penetran Test
•Impact Test •Ultrasonic Test
•Hardness Test •Dimension Check
•Visual Check

Non
Destructive
Destructive

Part & Component Inspection Laboratory & Calibration

Job desc: -Ensure Quality Component
-Ensure Semi finish part for
supplier
-Ensure quality before shipping
Facility: Lay out Machine, CMM Portable
(Faro), Laser Tracker, small tools, UT
machine
Job desc: -Periodic Test quality of IQT purpose
-Check quality related to material
-Manage and carry out calibration
process of measuring instruments
Facility: Vickers hardness test, rockwell
hardness test, microscope, poleshing machine,
micro cutting, standard block master.
 Procurement & Cross Sourcing Section
Sub Cont Development & Delivery Control Section
 Manager
GM Level Level

Procurement & Cross

Sourcing Section

Sub Cont
Purchasing Development &
Director in Charge
Department Delivery Control
Section

Cost Control Section

Department :
To purchase and procure
goods and service for
production that meet with
the specification, timely
delivery, and competitive
prices & to manage cost of
the company.
Section :
• To procure and purchase
goods and services for
Procurement &
production that meet with
Cross Sourcing
Section
the specification, timely
delivery, and competitiveness
price.
Sub.Cont • To develop subcontractors
Development & capability to meet with our
Delivery Control standard and control delivery
Section of purchased part
 Localization or Cross
Current New
Sourcing

GBN
Inspection Quality?

Hatsumono
(OK)
Insp Report
Part Selection Purchasing
Feasibility Study
Study Drawing
Print PO
( SQCD)
Send Drawing PPC
Supplier Map Sub-Cont

Trial Local Parts

(NG)
Insp Report + Kensha Hyo
Material
Control
 Komatsu
Indonesia
Exp : Index ± 1.4 Exp: Index ±1.41 + MF

KLTD 3PL
(KLC, Uchimura,
Goh Shoji)

Overseas
1. Topy (Japan)
Local Vendor Komatsu Group 2. WIL (India)
(Japan) 1. BKC 3. Berco (Italy)
2. KSC 4. Daikyo (Japan)
3. Etc. 5. Samyoung (Korea)
6. AMC (China)
7. JTEC/Toa (Vietnam)
8. UTC ( Thailand), etc
 • General product, fast moving, & small
Commodity (Ex: hose, wiring harness, & pin)

• Big & heavy (Ex: bucket, blade dozer, & harvester)

Attachment

• Hydraulic cylinder
Cylinder

Units
 Total by Brands Total by Brands
2016/June 2017/June
17% KOM 15%
KOM
32% CAT 14% 37% CAT
15%
HIT HIT
18% 18% KOB 17% KOB
17%

Total by Sector Total by Sector

2016/June 2017/June
12%
AGR AGR
18% 14%
CON 35% CON
14%
FOR 38% FOR
54% 15%
MNG MNG
 Customer Country

1 UT United Tractors Indonesia

2 KMSA Komatsu Marketing Support Australia Australia

3 KPAC Komatsu Part Asia Center Thailand

4 KEPO Komatsu Europe Part Operations Belgium

5 KCX Komatsu Castex Japan

6 KMSI Komatsu Marketing Support Indonesia Indonesia

7 KAC Komatsu American Corporation USA

8 Maxima Maxima Machineries Philiphines

9 KUI Komatsu Undercarriage Indonesia Indonesia

10 KSAF Komatsu South Africa South Africa

11 Hensley Hensley Industries USA

12 BKC Bangkok Komatsu Corporations Thailand

13 KIPL Komatsu India Private Limited India

14 UMW United Motor Work Malaysia

15 KGM Komatsu Germany Mining Germany

16 KME Komatsu Middle East UAE

17 SRMI Sakai Road Manufacturing Indonesia Indonesia

18 TFT Techno Fab Thailand Thailand

19 KLC Komatsu Logistic Corporations Japan

20 KRCC Komatsu Reman Center Chile Chile

21 MPS Mining Product Services Australia

22 KMM Komatsu Manufacturing Myanmar Myanmar

23 SPB/SP Surya Putra Barutama Indonesia

U

24 Merwa- Indonesia
I SK

25 KIM Komatsu Italy Manufacturing Italy

26 KMI Katsusiro Manufacturing Indonesia Indonesia

27 Marum Japan
a
Parts Customers
Body
Reman Distributors (United Tractors)

KMSI

KI
Cylinder

KRA/KI
Middle
machine
Big Machine

BKC
Middle
Excavator
Komatsu ltd.
 Simple KI business process
and cost control function

Achieve the
Komatsu Good product Competitive Komatsu
profit target
• Delivery on line Indonesia
Indonesia •Reliability of quality product price
Survival Competitive
COST
Advantage
Ability COMPETITIVE

Activity:
•Cost Reduction
Komatsu
•Level cost of
•Budget Control
product
Indonesia
COST CHECK & •Target act cost Survival
REVIEW •Cost improvement

Cost Control
Main Activity

Cost Control Activity

 • Cost of operating specific function/ departments
Capacity Cost • Not related directly to production
(CC) • Known as fixed / period cost

• Direct labor
Manufacturing • Variable overhead
Cost • All other overhead cost

Standard • Direct material cost

Variable Cost • Direct sub material cost
• Manufacturing cost
(SVC)
 Material Cost
•Negotiation price
•Localization
•Cross sourcing
(elated w/ purchasing)
Improve to control th e
standard consumption Control Direct Material & Process
Process Cost
•Direct hour ratio
Cost Reduction Activity •Process routing
(related w/ ME &
production)
Check & maintain the
standard of routing

Selling price to
customer Control Cost of Management report
(Related w/ PPC & Product (Related w/ Fin Acc.)
Marketing) Machine, Component & Improve the standard cost
Attachment yearly & report OVC)

Control of Expense (Overhead)

Each section Control Price

Budget Control (Related w/ LIC)
Budget Control
Overhead cost Import & Export
Expense
VISION : To become highly qualified and reputable
training center
MISION : 1. Enhance employees skill systematically
2. Training for new entry
3. Balancing Manpower
4. Suppliers skill level up
 CURRICULU TRAINING INSTRUCTO
BUILDING & FACILITIES
M PROGRAM RS

COMPETENC National CLASS PRACTICE

Y LIST Certified TRAINING TRAINING
Basic
Komatsu Ltd
Certified
COMPETENC KNOWLEDG
SKILL
Y LEVEL E
Intermediate
TRAINING
CATEGORIE PRE TEST EVALUATION
S Advance

TRAINING
MODULE OJT IN GEMBA

KI Employees
Trainee: abilities recorded in POST TEST EVALUATION
1. KI Employee HRMS
2. Group
Companies
3. Subcontractors
4. Apprenticeship COMPETENCY LEVEL CONFIRMED
 1. Improving quality
1. Priority for 02 process KI
Suppliers which products
produces over 2. Keeping quality
50% KI compo
03 through
2. Participants at competent welders
1. To minimize gap
least foreman
level, the goal
01 skill level of KI
employee with
being coach
suppliers
when returning
2. To enhance the
to work place Q competence level
U G P of suppliers
A U
O employees
L R
A P
I L O
F S
S
Y E
 General Service Operation
1. Warehouse and Administration
2. House Keeping
3. Ordering Administration
4. Food and Beverages
5. Security
6. Re3ceiptionist
Building Management and
Infrastructure
1. Employee Facilities
2. Infrastructure
3. BMI and Administration
4. Asset Management
5. Building
6. Mechanical and Electrical

Operation Cibitung Plant

1. Support Administration Cibitung
 To maintain
communication with
suppliers or vendors and
to handle complain
To maintain all 04
supporting
facilities and to
replace damage 03 05
goods
To make, run,
and expand
working
procedure of
To analyze cost of procurement
procurement and 02 06
RESPONSIBILITY
maintenance for
facilities to be
propose to the
financial 01
department To prepare monthly
budgeting report
To support every and financial report
operational activity in
company by providing
supporting tools
Function: Employee management with an emphasis on those employees as assets of the business.

Recruitment Development Performance Termination

• How to find the • Help employees to • Measure how well • Firing, layoff,
person who fit with develop their skill the employee’s pension
the organization • Ex: In class, OJT, performance
assignment & self
enhancement

1. Reward
2. Industrial Relation
3. Culture
Organizational Development
 Safety & Directors
Health

Environment Secretary
Safety Experts
(SHE Section)
Support Group
Companies

Plant A Plant B Plant C Plant D

Supervisor Supervisor Supervisor Supervisor

Safety Safety Safety Safety

Officer Officer Officer Officer
Core receiving Cleaning / Part
inspection Washing
Dis-Assy Evaluation Part Receivery

Machining
Process

INSPECTION
Machining
Inspection

Shipping
Assembling

Final
Bench
Packing Inspection Painting Washing
Test
 Preheating

MCS shot blasting TW Sub SAW Sub

TW Assy
Finishing 1 Inspection SAW Assy

Preheating

PWHT

Painting 1 Machining Inspection Finishing 2 Sub Assembling

MCS Top Coat

 Main Product
Attachment and Under Structure of big Size Machine

Boom

Arm Crawler Frame

Bucket By KRA
Center Frame
Blade
D156 and
D375

Straight Frame
D156 and D375
 Safety
Management
Activities

Quality
Management
Activities
PRIMARY FUNCTION

To grasp market demand,

plan and control Production &
production as well Delivery
warehouse control Management
Activities

Maintenance
Human
Resource
 Make & Distribute
Order Prepare Delivery
Document After Approving
Confirmation Process
By PPC Manager

Input Order
Data to Baan Monitor On Site Based Delivery
On Daily Production Plan Arrangement
Adjust
Line On Date
Does it
fit the
Daily plan?
Period
Small Meeting
Problem
Analysis
 Production Plan &
Making Control
Production
* Production Control
Plan
Input Production (Pouring & Finishing
Plan * Pouring Plan section)

* Finishing Plan * Pouring & Finishing

Production Plan
* Remain Delivery
* Delivery Plan
* Stock Report
* Molding, Pouring,
Finishing Capacity
Job Orientation Receiving Allocation Deliver

Prepare raw Placement in the To user

From supplier
material warehouse (production)
Paking and
Packing From production Export & Inhouse
Arrangement
 ICT

Infrastructur Operational
System Application IT Audit and
Analyst Development e and DBA
Planning

Primary Function: To provide IT based facilities for company’s benefits.

 As corporate secretary

As general counsel

As comercial lawyer

As case
management

As compliance
RESPONSIBILITY

Others
Independent appraisal service to
management measuring & evaluating
the effectiveness of the internal
control system

Process established by management to

provide reasonable assurance that
organizational objectives will be
achieved
 Independently review and
appraise control systems 01

Ascertain extent of
compliance with policies, 02
procedures, laws & regulations

Provide assurance to
management that agreed
policies are carried out 03
efficiently & effectively

Improve risk 04
management

Work in partnership with 05

the external auditors
 (Budget owner) (General Affair, Purchasing)
General Purchase
Application Orders
Ordering

(General Affair ,Purchasing)

Negotiation (General Affair,
& Sourcing Receiving material control)
Agreement

Vendor (General Affair,

Payment Accounting)
Selections

(Finance)
Analysis
Vendor
Requisitions
Evaluation
User
User

Planning Auditing Reporting Follow-up

REVIEW
 KI MTC established as a part of KI
challenging strategis in quality probling
solving leadtime reduction

Improving analysis skill of MTC man

power by collaboration with
universities for training and joint
analyisis

Technical assistance program from

MTC Background university (ITB) & monthly meeting
& with MEDC for analysis discussion
Organization
 Speed up investigation
problem

Research
collaboration
Function & Maintain quality
process & support
with Komatsu Activities Komatsu Group
Group University

Supporting process
improvment
activities
 Account
Billing Process / Cash
Receivable
invoice Management
Management

Trade Payment
AR Control
transaction process

Non trade Statement of Collection

transaction Account Process
 Payment
Invoice
Matching
Billing

Transaction

Transaction
Billing
AR Control
Collection
 Financial Master Data

Costu Vendo GL Excha

Use App Use App Use App Use App
mer r Accou nge
Form Form Form Form
Code Code nt Rate

BaaN
Transaction

Recorded Adjusted Finalized Closed Report Stakeholder

 Re-use

Ware
house

Core
New Center
 Strip Down Report
Receiving
Inspection cores
by QA receiving

Check Core condition, take photo

& put green tag

QA receiving make Receiving

Inspection Report (RIR)

Dis- Assy part and

Based on dis-
inspection part
assy check
sheet
NG Judgement
part & take
photo by QA

OK
PRS Order by Salvage
OK
Scrap parts process
mechanic Reusable parts

NG Ready to assy
QA SDR make
SDR

Send SDR via email to

Marketing, PPC &
Production
•Measuring test
•Bench test
•Leak Tester
•Dyno Test
•Final check
-Unit and attachment marketing is to sell
machine, component timely to satisfy customer
needs
-Reman marketing is to sell Reman component
in efficient and effective way by developing
new market and new components
-Working gear is to develop of attachment
timely to satisfy customer needs
 Customer Distributor Komatsu Subsidiary KRI
Adjust OV Schedule
Next 6-month
Summarize OV Schedule
(Purchase Order) (Purchase Order) Rolling Forecast

(Purchase Order
2months befoore ship
month)
Production Plan
Parts Preparation

Core return Leadtime is 3 months

from finish good shipment date
Installation

CorePreparation

Production
Document

Shipping Shipping Shipping

Finish Good
Finish Good
Finish Good Finish Good

Shipping Shipping
Shipping

Core Return Core Return Core Return Core Return

Manufacturing Engineering
Primary Function

To prepare the facilities

(equipment. machine, jig,
fixture, etc), to introduce
new model /part (exclude
Foundry), to prepare
investment plan &
utilization
 Structure
Manager :
Widayat Raharjo
(conc.)

Asst. Mgr:
Tercipta Tarigan

Trial & Preparation Facility & Fix Asset Control Trial Facility & Preparation (CIB)
Coord: Dedy Hastomo Coord: Tommy Lufthanza Coord: Nur Siroj

Drawing Control Project & Facility Process Preparation &

Layout
Suwarti Ashady
1. Nur Siroj (conc.)
2. Anwar
3. Sudarto
Process Plan Improvement Control
1. Dedy Hastomo (conc.) Nanang Yahya
2. Indra Nainggolan

Facility Preparation
Manufacture Jig & Facility Tommy Lufthanza (conc.)
1. Sarjono
2. Agam Sriadi
Facility Preparation (FDR)
Andy Bayu

Design Jig & Fixture

1. Sigit Jarkasih
2. Supriadi
 Activities of Manufacture Engineering

Design processing and production methods New process and equipment development

Design of special tools and equipment Determining work methods for each area

Planning operation sequence Determining production standards for all process

Specifying machines and equipment to be used Determining machine capacities and number of machine

Trying out of tools, etc Install or move machinery and equipment

Mechanization and automation Plan for building changes or construction

Production capability analyzes Fixed asset controlling

 Bussines Flow Process
Business Flow Process for Trial Production

Trial Prod. Material

Customer Preparation Receiving Inspection Customer

Order Material Trial Storage &

Confirmation Ordering Production Delivery

Business Flow Process for Regular Production

Mass Material
Production Receiving &
Customer planning Supply Inspection Customer

Order Material Mass Storage &

Confirmation Ordering Production Delivery

Manufacturing Engineering
Activities
Maintenance
 Organization Structure

Manager
Widayat R.

Cilincing Plant : Cibitung Reman Plant

& Reman Cyl
M. Hasanul Balikpapan :
Dasir

Fabrication Plant : Foundry Plant : Hydraulic Plant TQM Section, Adm,

Budget, Part Control
Slamet Edi Warsih R. Wiwono & Kaizen Fabrication Adm, Budget, and Part
Foreman Foreman Foreman Ade S. Cibitung & Control, Maintenance
Balikpapan Building
Sutrono M. Syadul
 Primary Function
Safety Management
Management of safety risk during operation
Activity

Management of defect in the plant

Quality Management
Activities

Management of feedback of defect in the

market

Primary Function : To maintain

production facility in timely
manner and optimum cost with
good performance Management of production plan

Production and cost

management activity

Management of cost improvement progess

Management of people to obey the company

rule

Human resource
development activities

Management of the QC ability improvement

Section Maintenance

Spare Part Control

Breakdown
Maintenance

Periodic
Maintenance
Plant Tour Photo

Jig Preparation

Compresor

Genset
THANK YOU