1619 1819 1970 70 1990 7-1
74 75 79 80 85 86 88 89 90 91 92 93 94 95 96 97 AB 1001003 00 7-2
Central Bureau of Statistics 600t/ 50t/ 600 1,199t/5099t/ 1,200 3,599t/100299t/ 3,600 5,999t/300499t/ 6,00011,999t/500999t/ 12,000t/ 1,000t/ 7-3
AB 35 No.457 73 65,000 5,000 4,000 4,000 10,000 30,000 30,000 2,000 150,000 24 4 1 0 3 3 5 0 40 30 0 40 30 5 320 5 20 450 A B23A CA D CD 199522 13,700 7-4
1995 % 100US % 104,246 47.2 1,048.8 70.0 35,580 16.1 34.8 2.3 30,304 13.7 33.8 2.3 11,558 5.2 56.6 3.8 6,547 3.0 86.3 5.7 5,275 2.4 51.8 3.5 27,556 13.4 191.5 12.4 221,066 100.0 1,503.6 100.0 Central Bureau of Statistics 1995 % 100US % 3,733 27.2 19,710 35.4 2,858 20.9 10,110 18.2 490 3.6 3,961 7.1 1,380 10.1 3,569 6.4 1,314 9.6 4,967 8.9 1,167 8.5 1,849 3.3 949 6.9 2,690 4.8 1,831 13.2 8,791 15.9 13,722 100.0 55,647 100.0 Central Bureau of Statistics 19901995 11151995125,000 7-5
1990 1991 1992 1993 1994 1995 47,400 53,489 57,834 65,396 74,022 85,526 3,050 3,725 4,693 2,748 3,274 3,798 5,580 5,914 6,328 7,984 8,753 9,456 56,030 63,128 59,474 78,506 89,149 102,649 1,318 1,440 1,627 1,716 1,900 2,190 510 571 625 635 699 779 36 38 40 86 99 126 1,864 2,049 2,292 2,437 2,698 3,095 7,689 8,765 10,342 11,593 13,229 15,405 2,366 2,675 2,982 2,846 3,235 3,612 86 93 97 93 95 105 68,035 76,710 85,187 96,237 108,406 124,866 1.00 1.13 1.25 1.41 1.59 1.89 12.75 % 11.05 % 12.97 % 12.64 % 15.18 % CIC 70 1995 JICA 7-6
(kg/) 300kg/190kg/ 500600 kg/ (A) 10,000/ 1994 (B) 1,000/ 1993 (C ) 100/ (B)/(A) 1 kg/ (B)/(C ) % 1,050 3,300 6,682 314 49.4 44 150 1,450 330 10.3 217 700 1,305 536 * 53.4 145 800 12,000 667 * 6.7 43 80 350 186 ** 22.9 7 20 64 286 31.3 7 10 140 143 ** 7.1 32 60 150 188 ** 40.0 JICA 7-7
7-8
OJT OJT 7-9
7-10
7-11
JICA 7-12
AB 1212/h 7-13
1724/kg 2228/kg 19/kg 18/kg 2839/kg 2531/kg 34/kg 22/kg Fe-Si 88100/kg 80/kg Fe-Mn 7277/kg 80/kg Fe-Cr 110120/kg 150/kg 160190/kg 125/kg 1.3-1.5 94105/kg 3.05.5/kg 78/kg 2233/kg 17/kg 1.3-1.5 1.3-1.5 (,) 65kg/cm 2 1.3-1.5 26-38/kg (,) 138/kg 1.3-1.5 11.6/kg 35/kg (,) 8.09.5/kg C>90%7% 4045/kg 70/kg 7.78.8/kWH 5.46.8/kWH JICA 7-14
1010 7-15
SEM (IDMMI=MIDC) (LIPI) () UPT() 7-16
7-17
A455 30 7-18
162 UPT 37 4 7-19
*** * 1 P.T. Kamatsu Indonesia 2 P.T. Bakrie Tosanjaya 3 T. Barata Jakarta Foundry C enter (4,000) B 4 P.T. Geteka Founindo 5 PT. Toyota Astra Motor En gine Plant 9,000 A 6 PT. A. T. Indonesia (8,400) 1997 7 PT. KSB Indonesia 8,400 A 8 C.V. Bakti 1,800 A 9 PT. Bina Usaha Mandiri Mi zusawa 10 PT. Tatung Badi Indonesia * A70%B50%50% ** PDCGDCLPD *** ABCD 7,200 A A A B A (8,400) A A A B A B A B B (6,000) A B A B A 2,400 A 4,000 A A A A A A A B A A A B A A B C B B A B A A A B A 7-20
*** * 11 PT. Daya Baru Agung 1,200 A 12 P.T. Asama Indonesia Manu facturing A 13 P.T. Baninusa Indonesia A A 14 PT. Pindad Forging & Casti ng Divi. 3,600 B 15 PT. Bara Multi Metalika 3,600 A 16 P.T. Maju Warna Steel 17 P.T. Barata 'Gresik ** 1,800 C GDC B 18 P.T. Pakarti Riken Indonesia 19 P.T. Boma Bisma Indra 20 P.T. Agrindo unit Foundy 21 C.V. Logam Makmur FC A C B A B A A A B A A B B B A A B B B A A (3,600) C B B B B B B B 34,000 A A A B A (2,000) C B B B C 1,200 C B B B B B C C 7-21
22 P.T. Aneka Adhilogam Kary a 23 Sinar Industri 24 P.T. Itokoh Ceperindo 25 P.T. Suyuti Sidomaju 26 P.T. Karya Rini 27 P.T. Boja Kurnia 28 P.T. Federal Nusametal 29 P.T. Kyowa Indonesia 30 PT. Honda Prospect Engine Mfg. 31 PT. Edico Utama *** * FC 2,400 A FC 960 A FC FC FC PDC PDC PDC GDC B B B B B B C B 1997 A A A 1,200 A B B C C 600 A C B C C A (3,500) A A 840 A 480 A B B B B A A B A A A B A A A B A B B C B 7-22
*** * 32 PT. Inkoasku 700 A LPD 33 PT. Hashiba Indonesia 5 C LPD 34 P.T. Berdikari ** A PDC 35 Steanco Putera Perkasa 36 Tunas Abadi Teknik 37 P.T. Arsimelin Megan Indust ri Cu GDC PDC 480 B B A A B A A A A B B B A B B B B C C C B C C B C C C 7-23
7-24
7-25
7-26
7-27
7-28
7-29
7-30
7-31
40 301995702005 1/3 221,000/199574,000/2005 3 13,700/199541,000/2005 UPT 35 0.51 7-32
1500 F1 500x350m/m 100kg/ 7-33
APLINDO a. b. c. a. b. CAD/CAM c. (FC) () 7-34
(FC) (FC, FCD) (FC, FCD) () 7-35
19705 2530 24,000 600230 7-36
7-37
7-38
(kg/) 19982000 20002.537 19885 7-39
19885 7-40
7-41
A B C 7-42
7-43
7-44
50 30 7-45
7-46
1995 1998 2000 25,000 50,000 75,000 7,600 18,800 33,000 30% 40% 50% JICA 7-47
Hand pressfoot press NailRivet 1970 REM(Replacement Equipment Manufacturing) 1980 REMOEM REM Jakarta Surabaya 7-48
REM 500 mm 300 500mm30300mm30mm 7-49
OJT Off-JT Capacity Capacity limitation 7-50
70 TQCSQC(Statistical Quality Control) 7-51
REMO EM 7-52
1950 19501965 19651980 SKD11SKH5157WC-D 1980 15 0.3 1.2mm Metal stamping30300tf 7-53
Hydraulic press JICA 10 Cottage industry 7-54
4.5 5.0 International brand International market 3.8 4.4 International brand Local market ASEAN 3.0 3.7 Local brand Local market ASEAN 2.9 Local market JICA 1512 3 12 3 7-55
2.9 3.1 2.8 3.1 3.0 3.2 3.0 2.3 3.1 2.9 2.8 2.3 2.2 2.6 2.5 2.5 2.9 2.2 3.3 2.7 2.9 2.7 2.2 2.9 2.7 2.8 2.9 2.2 2.9 2.7 2.6 2.9 2.2 2.3 2.5 2.6 2.3 2.2 3.4 2.6 2.7 2.5 2.2 2.6 2.5 2.8 2.7 2.2 2.6 2.6 2.9 2.8 2.2 2.6 2.6 2.1 2.2 1.7 2.4 2.1 2.7 2.7 2.2 2.8 2.6 JICA 4.2 3.6 4.1 3.4 3.8 3.9 3.3 2.7 3.3 3.3 3.2 3.4 3.5 3.7 3.5 3.8 3.4 3.4 3.5 3.5 JICA 7-56
3.8 3.4 3.4 2.8 3.5 3.5 2.7 2.7 2.6 2.2 JICA 7-57
Enginee rtechnicianoperator 7-58
Start 7-59
()(JMSA)1983 50008000 EngineerTechnician EngineerTechnician 7-60
Spcc, 100 0.6t [mm] One process work Compound Work Transfer work Robot work) Progressive work 5000 8000 () 7-61
() (8) (8) (8) () (8) (2-3) () () () 1995 2000 2005 2010 JICA 7-62
() () () (8) (8) () (8) (8) IC () () JICA 7-63
19948008 1986 1987 1988 1989 1990 1994 544 558 654 663 687 800 5.0 5.1 6.0 6.2 7.6 8.0 CICAPINDO 199630 501050 7-64
1996 3050 Jabotabek 1 99570 1986 1987 1988 1989 1990 1992 1995 16.5 24.6 35.6 45.8 55.0 65.0 70.0 JETRO 909 5510 PP, PE, PVC, PS, ABS 9095 PA6, POM, PC, PBT 510 JICA 7-65
APINDO 9 0 7-66
7-67
OJT APIND O1996 OJTPOLMAN POLMAN 7-68
7-69
Man to Man Machine 10 JICA MI 7-70
7-71
(T2) (T1) 10 11 JICA 7-72
3070 7-73
NC CAD/CAM 7-74
PPPEPVCPSABS1996 HDPERp 2,650/kgABSRp 3,500/kg PT.Petrokima Nusantra Indo PE PT.Tripolyta Indonesia PP PT.Chandra Asri PP, PE PT.Polychem Lindo PS POLYRON PT.Pacific Indomas Plastic Indonesia PS STYRON PT.Strindo Mono Indonesia PS PT.Asahimas Subentra Chemical PVC ASNYL JICA POMPBTPCPA6PA661996 100 100 100 7-75
JODC QC POLMAN APINDO ITB OJT 7-76
JICA 7-77
JICA ASEAN ASEAN 7-78
2.0-3.5 2.0-3.0 JICA 7-79
SNI JICA 7-80
SNI JICA 7-81
7-82
7-83
Functional Parts Standard Parts Exclusive Parts 7-84
7-85
7-86
JICA 7-87
7-88
7-89
5 7-90
Arm(Kick Starter) 7-91
7-92
7-93
JICA (a) 7-94
(b) (c) 7-95
Resources of information Frequency 1 Client 5 2 Machinery & EQPT supplier 5 3 Book & brochure 3 4 In-house 2 5 Grouping firm 2 6 Educational institution 1 7 Not answerable 1 JICA 7-96
7-97
7-98
7-99
7-100
7-101
) 300 7-102
372 7-103
Ni-CrCu-Ni-Cr 7-104
JODC JODC QDC(Quality, Delivery & Cost) SKS, SKD, SKT, SKH PVD(physical vapor deposition)cvd(chemical vapor deposition) 7-105
1) 7-106
PMA PMDN27.5% Non-PMA/PMD24% PMDN 11 (27.5%) 19.4 (48.5%) 9.8 (24.5%) 40 PMA 13.4 (34.4%) 19.6 (50.3%) 5.6 (14.4%) 39 Non-PMDN/PMA 32.4 (24.0%) 65.6 (48.6%) 36.6 (27.1%) 135 JICA 2) 7-107
43%2 3.3% 36 55 71 61 1 32 5 137 25 29 47 26 0 11 2 74 7 6 13 9 0 5 1 22 32 56 71 48 1 25 5 125 19 43 69 56 2 26 2 113 6 16 25 15 1 10 2 39 10 12 23 18 1 12 1 40 4 12 16 14 0 3 1 30 45 78 111 90 2 35 5 201 63 (23.3%) 99 (36.7%) 145 (53.7%) 116 (43%) 2 (0.7%) 46 (17%) 7 (2. 6%) 270 JICA 7-108
3) 29143%125 7-109
61 (41.5%) 147 39 (48.1%) 81 10 (40%) 25 56 (42.1%) 133 54 (45.8%) 118 14 (35.9%) 39 19 (44.2%) 43 9 (31.0%) 29 89 (41.6%) 214 125 (43%) 291 JICA 4) 49 7-110
18.6%2229.8%37 20026.2%1751.4%36 36.9% 20.8% 49 22 (18.6%) 66 (55.9%) 30 (25.4%) 118 (100%) 50199 9 (18.8%) 26 (54.2%) 13 (27.1%) 48 (100%) 200 17 (26.2%) 34 (52.3%) 14 (21.5%) 65 (100%) 48 (20.8%) 126 (54.5%) 57 (24.7%) 231 (100%) JICA 49 37 (29.8%) 54 (43.5%) 33 (26.6%) 124 (100%) 50199 17 (34%) 20 (40%) 13 (26%) 50 (100%) 200 36 (51.4%) 21 (30%) 13 (18.6%) 70 (100%) 90 (36.9%) 95 (38.9%) 59 (24.2%) 244 (100%) JICA 7-111
5) AFTA MIDC 33 (41.3%) 27 (33.8%) 23 (28.8%) 17 (21.3%) 11 (13.8%) 12 (15.0%) 3 (3.8%) 80 JICA 7-112
6) 60% 1040%15 15 93 (39.2%) 610 50 (21.1%) 1120 37 (15.6%) 2150 26 (11.0%) 51 31 (13.1%) 237 (100%) JICA 7-113
7) 2025 60% 36%75 127 (61.4%) 75 (36.2%) 54 (26.1%) 52 (25.1%) 50 (24.2%) 46 (22.2%) 35 (16.9%) 28 (13.5%) 12 (5.8%) 5 (2.4%) 4 (1.9%) 3 (1.4%) 7 (3.4%) 209 JICA 7-114
7-115
7-116
7-117
7-118
Quality Control Flowchart,In-ProcessChecksheet,Intermediate ProcessCheksheet Defective Ratio DO, CHECK, ACTION DO, CHECK ACTION 7-119
Final I nspection Production Control Board Control BoardSchedule Control Delivery ControlSchedule Control Check 7-120
7-121
TPM 7-122