Production Process COMPANY PROFILE

3.3 Production Process

Production Facilities PT. Dow AgroSciences Indonesia Medan Plant produces herbicide and insecticide products. The production facilities also separate between those products to prevent cross contamination between insecticides and herbicides. There are 3 lines filling for herbicides products which are: a. Line 1: dedicated to produce DMA b. Line 2: share facility to produce Oil Based Herbicides c. Line 3: share facilities to produce water based herbicides There are 3 lines filling for insecticides products which are: a. Line 1: dedicated to produce Durban200EC b. Line 2: share facility for water based insecticides products c. Line 3: share facilities for oil based insecticides products In each production process the activities is divided into formulation and packaging lines. 1. Formulation Formulation process is a process of blending and mixing of raw materials including an active raw material. There is a standard operating procedures and recipe for each product. The recipe will give information about which materials that have to charge in, how many, how long the agitation process and what are specification target to achieve. Devi Adhriany Rahayu :Building Model Of Basic Stability For Productivity Improvement Journey In PT.Dow Agrosciences Indonesia By Utilizing Value Stream Mapping VSM In Production Shop Floor, 2009 USU Repository © 2008 Equipment for formulation processes are tanks, agitator, pumps, piping and electrical panel control, etc. 2. Packaging Lines Packaging lines is a process where products after formulation are packed into specific small container. The packaging line is start from empty bottles, filling machine, capper machine, induction sealing, labeling machine, weighing, cartonizing and palletizing. To support formulation and packaging lines, plant also have utilities unit such as water treatment, diesel generator, compressors, nitrogen generator. Raw materials and finish products stored in dedicated warehouses. Raw Materials Materials to support formulation and filling activities supplied from local Indonesia suppliers and also imported from outside Indonesia like United States, Europe and other ASEAN countries. Materials can categorize as follow: 1. Active Raw Materials Active raw materials are raw materials that have a very important effect to the products. Impact to efficacy or knock down of target is one of measurement of pesticides products. That’s why the pesticides manufacturer must register the active material content on each product to government thru Agriculture Department. Active material usually made in other Dow technical plant in over the world Devi Adhriany Rahayu :Building Model Of Basic Stability For Productivity Improvement Journey In PT.Dow Agrosciences Indonesia By Utilizing Value Stream Mapping VSM In Production Shop Floor, 2009 USU Repository © 2008 2. Special Raw Materials Special raw materials mean this raw material has a very specific function in the product formulation such as emulsifier, thickener or anti bacteria materials. 3. Addition Raw Materials Addition raw materials usually only have a very small percentage in the pesticides formulation with a very small impact to product quality such as color agent. 4. Packaging Packaging is material to pack the product in for customer use. Packaging materials are bottles, carton box, closure cap, drum, labels, etc. Products Quality and Specification Dursban 200EC and DMA6 are two products that very popular in market, both of them have a brand image in farmer’s eyes. To maintain brand image, it is very important for company to keep maintaining products quality. Medan Plant has a comprehensive quality system that documented in “Plant Quality Manual Book” that must align and comply with “Operating Discipline Management System” a high level corporate direction. All products specification comes from a very deep research and analysis. Dow AgroSciences has a research centre in Indianapolis USA to ensure Dow makes products that meet or even exceed customers expectation. Devi Adhriany Rahayu :Building Model Of Basic Stability For Productivity Improvement Journey In PT.Dow Agrosciences Indonesia By Utilizing Value Stream Mapping VSM In Production Shop Floor, 2009 USU Repository © 2008 Summary This chapter represents short profile of company where research will be conducted such as company history, organization and management, as well as production process that are important for reader to get a view of company’s environment for more understanding later parts of this paper. Devi Adhriany Rahayu :Building Model Of Basic Stability For Productivity Improvement Journey In PT.Dow Agrosciences Indonesia By Utilizing Value Stream Mapping VSM In Production Shop Floor, 2009 USU Repository © 2008 51

CHAPTER IV METHODOLOGY