End-to-end visibility from Persiapan to Finishing ? GM & Director Level
Preparation
Pre-Press
CD & CX
UV, Lam, Hotstamp
Diecut, Inspect, Pack
| Stage | Machine | 05 May | 13 Jul | 14 Jul | Trend |
|---|---|---|---|---|---|
| S1: Persiapan | Wohlenberg | Cutting SB | PDCGP, Hallmark | — | Intermittent |
| Die Cut | — | — | — | Support | |
| Tinta | 3 jobs RI | 3 jobs RI | 4 jobs (3 RI) | Consistent | |
| S2: Pra Cetak | CTP | — | — | — | Not reported |
| Eye C Profiler | — | — | — | Not reported | |
| S3: Offset | CD 102 | 14,000 | Setting | 5,000 | Variable |
| CX 104 | 10,000 | 12,300 | 2,000 | Declining | |
| S4: Finishing 1 | UV Shengshun 1 | Shift 3 | MJC | — | Mostly Down |
| UV Shengshun 2 | Shift 3 | MJC | — | Mostly Down | |
| Youbond (Lam) | 1,900 | OFF | OFF | Chronic Idle | |
| S5: Finishing 2 | MK (Diecut) | OFF (sparepart) | 2,400 | 10,000 | Recovering |
| Novacut (Diecut) | 36,000 | Setting | Setting | Setup-heavy | |
| Diana Eye | OFF | OFF | Setting | Mostly Down | |
| Ambition (FG) | 52,000 | 43,000 | Selesai+Setting | Top Performer | |
| Rolam (FG) | Setting | 21,500 | 14,000 | Ramping Up | |
| Packing | Manual/Gaplok | 5 tasks | 5 tasks | 8 tasks | High Load |
Stage 4 (UV, Youbond) at 22% utilization. All 3 machines OFF or idle on 14 Jul. This creates a bottleneck preventing printed sheets from flowing to Finishing 2. Work-in-progress is likely piling up before this stage.
Total output dropped from 80,200 (13 Jul) to 27,000 (14 Jul). Root cause: Finishing 1 machines (UV1, UV2, Youbond) all OFF simultaneously. This is not a demand issue ? it's a capacity failure at a critical pipeline stage.
Automatic inspection machine OFF 2 of 3 days. If Diana Eye is down, quality inspection falls back to manual ? slowing Finishing 2 throughput and increasing defect escape risk. Maintenance review required.
Delivered 95,000+ pcs across 2 active days ? 42% of total output. As the primary folder gluer in Finishing 2, Ambition is the backbone. Preventive maintenance must be priority #1 to protect this capacity.
Stage 3 (Offset) produced 53,300 pcs but Stage 4 (Finishing 1) can't keep up. This creates WIP inventory buildup between stages. Consider outsourcing more Finishing 1 work (hotstamp, emboss already outsourced) or adding shifts to UV/Youbond.
Manual tasks increased from 5 to 8 across 3 days. As automated machines (Diana Eye, UV) go down, work shifts to manual. This is a leading indicator of labor cost escalation and quality risk. Automation investment needed.
MK went from OFF (waiting for sparepart belt timing) on 05 May to 10,000 pcs on 14 Jul. Good recovery. However, Novacut (also diecut) spent 2 of 3 days in "setting" ? review whether changeover time can be reduced.
CTP and Eye C Profiler are not appearing in WhatsApp reports. Either they run silently, or operators aren't reporting them. This creates a blind spot ? GM cannot see pre-press throughput or identify delays before printing starts.
Immediate maintenance audit on UV1, UV2, Youbond. This is the #1 bottleneck. Consider outsourcing UV work if machines can't be restored.
Request incident report from production supervisor. Why were all Finishing 1 machines OFF simultaneously? Material? Manpower? Breakdown?
Mandate all stages (including CTP, Eye C) in WhatsApp reports. Current blind spots prevent full pipeline visibility. Create a template.
Manual packing workload trending up. Evaluate ROI on automation for sorting, gluing, and packing. Also fix Diana Eye to restore auto-inspection.