Kreator Volume 12.
Number 2, 2025 pp.
P-ISSN: 2354-9505 E-ISSN : 2548-9542
Open Access: https://doi.
org/10.
46961/kreator.
Reducing Sorting and Return of Sauce Packed Products As a Green Production Strategy In Flexible Packaging Industry Ali Mustofa1.
Handoko2 1Industrial Engineering.
Pramita Indonesia University.
Tangerang.
Indonesia 2Production Department.
PT ABC Tbk.
Tangerang.
Indonesia
ARTICLE INFO
ABSTRAK
Industri manufaktur kemasan fleksibel (Flexible Packagin.
Article history:
menghadapi tantangan signifikan terkait mutu produk, yang Received December 12, 2025 berdampak pada tingginya angka sortir dan retur serta Revised December 23, 2025 Accepted December 31, 2025 mempengaruhi kelancaran pengiriman.
Tingginya angka return Available online December 31, menjadi perhatian utama karena tidak hanya menurunkan kepuasan pelanggan, tetapi juga memengaruhi pencapaian Key Performance Indicator (KPI) perusahaan, yaitu On Time Delivery dan Zero Return.
Kata Kunci:
Analisis awal menunjukkan bahwa proses Slitting merupakan titik Flexible Packaging.
Slitting.
Sortir, kritis dalam proses produksi kemasan fleksibel, dengan dua masalah Retur.
Paper core utama, yaitu gulungan tidak rapi dan paper core sempit.
Kedua masalah ini menjadi penyumbang terbesar terhadap angka sortir dan Keywords:
Flexible Packaging.
Slitting.
Sortir, retur pelanggan.
Untuk mengatasinya, perusahaan menerapkan dua Retur.
Paper core pendekatan, pertama yaitu dengan menghilangkan akar penyebab teknis dari kedua masalah tersebut, dan kedua dengan mencegah agar masalah tidak lolos ke pelanggan, sekaligus mengurangi pemborosan dan potensi pencemaran lingkungan menggunakan metode fish bone diagram dan root cause analysis.
Hasil This is an open access article implementasi menunjukkan perbaikan yang signifikan.
Rata-rata under the CC BY-SA license.
sortir per bulan turun dari 18 roll menjadi 7 roll, dan pencapaian retur Copyright A 2025 by Author.
yang sebelumnya mencapai 6 roll berhasil ditekan hingga 0 roll Published by Politeknik Negeri selama periode Mei 2025 hingga September 2025.
Melalui upaya Media Kreatif Continuous Improvement dilakukan oleh perusahaan, perusahaan berhasil mengatasi masalah gulungan tidak rapi dan paper core sempit yang sebelumnya menyebabkan retur produk dan penurunan kualitas.
Dengan langkah-langkah yang terukur dan terdokumentasi, perusahaan tidak hanya mengoptimalkan proses produksi, tetapi juga meningkatkan kepuasan pelanggan secara signifikan.
Keberhasilan ini mencerminkan komitmen perusahaan terhadap kualitas dan keberlanjutan operasional yang efisien dan ramah lingkungan ABSTRACT The flexible packaging manufacturing industry faces significant challenges related to product quality, resulting in high sorting and return rates and impacting smooth delivery.
High return rates are a major concern as they not only reduce customer satisfaction but also impact the achievement of the company's Key Performance Indicators (KPI.
of On-Time Delivery and Zero Returns.
Initial analysis showed that the slitting process was a critical point in the flexible packaging production process, with two main problems, namely a messy roll and a narrow paper core.
These two problems were the largest contributors to the number of customer sorting and returns.
To overcome these, the company implemented two approaches, first by eliminating the technical causes of both problems, and second by preventing the problems from being passed on to customers, while reducing waste and potential environmental pollution using fishbone diagrams and root cause analysis methods.
The implementation results showed significant improvements.
The average monthly sorting rate decreased from 18 rolls to 7 rolls and returns were reduced from 6 rolls to 0 rolls between May 2025 and September 2025.
Through Continuous Improvement efforts, the company successfully addressed issues with messy rolls and narrow paper cores that previously led to product returns and *Corresponding author E-mail addresses: kkmspektra.
fptangerang@gmail.
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quality degradation.
With measurable and documented steps, the company not only optimized its production processes but also significantly improved customer satisfaction.
This success reflects the companyAos commitment to quality and sustainability, efficient and environmentally friendly INTRODUCTION Companies that can win the competition are those that consistently find ways to advance.
One way to determine whether a company is advancing is through its productivity growth.
Productivity is the number of units of goods or services produced by employees in a given period of time using various types of machines and equipment available in the workplace (Pardede, 2.
Many companies are looking for effective and efficient methods or methods in increasing productivity.
Productivity cannot be measured without a standard or benchmark, namely Key Performance Indicator (KPI).
In the modern manufacturing industry, the biggest challenge is not only maintaining productivity but also ensuring efficiency while maintaining environmental sustainability.
For many years, the flexible packaging manufacturing industry in Indonesia has faced classic product quality issues, including sorting and high return rates.
This situation not only hinders production and shipping, but also creates significant costs and waste, contrary to the spirit of the green industry, as stipulated in the Regulation of the Minister of Industry of the Republic of Indonesia No.
55 of 2020 concerning Green Industry Standards.
The gradual implementation of the green industry will help increase the efficiency, profitability, and competitiveness of industrial companies in the global market (Lina Saptaria.
Sopiah, 2.
Green management focuses on management efforts to reduce the impact of environmental problems arising from organizational activities.
The implementation of green industry is carried out through the concept of green production through the application of 4R, namely Reduce .
aste reduction at the sourc.
Reuse .
aste reus.
Recycle .
aste recyclin.
, and Recovery .
eparation of a material or energy from a wast.
(Aminah.
Yusriadi, 2.
The clean industrial system is also expected to provide savings in terms of environment and economy, such as the application of green production in a tofu factory that has been improved so that it results in water savings per month which automatically also reduces production costs incurred (Rahayu, 2.
It is also stated that green production is the overall environmental efficiency of a company through a comprehensive pollution prevention approach (Geng et al.
, 2.
According to Wu et al.
, all forms of human activity certainly have risks, including green production.
Therefore, risk management is needed to address all forms of risks that may occur in the future.
Christiani, 2017 has conducted an industrial environmental performance measurement in Indonesia based on green industry standards for the medium industry category, so this time for large industries operating in the plastic packaging category, it will be seen an overview of what has been done in the production process based on green industry criteria.
Recent developments in the green industry by determining indicators as a tool to prevent or reduce with better product design, better process optimization, better monitoring, better training and management, combined with developing and uniform government regulations, applicable to industrial and business facilities (Klemes et al.
, 2.
High sorting and customer return achievements are a major concern for the company because they not only reduce customer satisfaction, but also affect the achievement of the company's Key Performance Indicators (KPI.
, namely On Time Delivery and Zero Return.
Tabel 1.
Percentage of Untidy Roll Sorting Problems by FG Product Type
in the period Jan 2025 - April 2025
Product
Type FG
Problem
Desc
Sauce Pack
Noodle Group Non
Noodle Oil Pack
Messy Messy Messy Messy Total
Number
of FG
Std Roll
length of roller FG
Total Roll
Length
% Sortir
41,65
34,72
17,18
6,45
Ali Mustofa/ Reducing Sorting and Return of Sauce Packed Products As a Green Production Strategy In Flexible Packaging Industry Kreator Vol.
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Based on Table 1 above, the problem of messy rolls on Sauce Pack products has the highest percentage of separation problems compared to other types of products.
Figure 1.
FG Roll Sauce Pack Product problem, messy roll Tabel 2.
Number of FG Roll Sauce Pack product returns in the period Jan 2025 - April 2025 Return Problems Number of FG Rolls Narrow paper core Asymmetrical cut Torn Total Based on Table 2 above, customer returns due to narrow paper core issues for Sauce Pack products are the highest compared to other return issues.
Narrow paper core issues involve paper cores with defects on the inner surface, reducing the core diameter, making them difficult for customers to use during production.
Through a Continuous Improvement (CI) activity titled "Reducing Sorting and Returning Sauce Pack Products as a Green Production Strategy in the Flexible Packaging Industry," a leading Indonesian flexible packaging company.
PT ABC Tbk, identified the interleaving process as a critical point in the production process, with two main issues and messy paper.
Both of these issues significantly contributed to the number of sorting and customer returns for Sauce Pack products.
METHOD
To address the above-mentioned issues, two approaches have been taken: first, eliminating the technical causes of both issues, and second, preventing the issues from reaching the customer, while reducing potential waste and environmental pollution.
Silva .
conducted research on the most suitable methodology for assessing green production, namely the standard methodology, compared to various other individual methods because its methodology is broader and easier to implement than other individual methods.
It can be said that the main focus of the development of the standard methodology is the planning phase of the PDCA (Plan.
Do.
Check.
Actio.
The improvement stages carried out in this CI activity are as follows:
Plan Stage Conduct field observations and data collection to formulate the background of the problem, analyze potential causes of the problem, determine improvement targets, and create improvement plans.
Do Stage Carrying out repair activities by testing the use of air shafts and friction ring type shafts in the sauce pack product process for 20 working days.
Shaft type testing is carried out by directly observing each activity during the process, starting from observing the work methods carried out by the operator, the equipment used, until the final results of a process in the activity as well as testing various existing core plug residues .
sing core plug Ex jumbo roll Plain Raw Kreator P-ISSN: 2354-9505 E-ISSN : 2548-9542 Kreator Vol.
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Material Fil.
with the FG dropping test method vertically .
eight approximately 100 c.
and horizontally .
eight approximately 50 c.
Check Stage Conduct an evaluation of the results of the improvement by conducting a Why-Why analysis using the 5W 1H method, conducting an improvement impact assessment analysis .
efore and after the improvemen.
, and conducting a financial review analysis .
ost savings Acton Stage Carrying out standardization and follow-up on improvement results by creating new process procedure standards based on the achievement of improvement results and carrying out socialization of improvement activities in other plant work units.
RESULT AND DISCUSSION
Tabel 3.
Analyze the potential cause of the problem Factors Item Operator's ability to operate the slitting Standard Operators work according to SOP and WI Actual Conditon Efficient Material Paper core No change in inner diameter There is a change in the inner diameter Problem Methode Machine Parameter Produces rolls with good roll flatness Suitable Machine Roll flatness stability during the slitting process in the shaft rewinder Unstable roll flatness process in shaft Problem Man Taper tension according to existing WI Stable roll flatness during the grooving process in shaft Remark Suitable Based on Table 3 above, from a material perspective, the changing inner diameter of the paper core causes the Sauce Pack product to have a narrow paper core.
Furthermore, from a machine perspective, the unstable roll flatness causes the Sauce Pack product to have a messy roll.
Based on the analysis of these potential causes, the next step is to analyze the cause-effect relationship using a fishbone diagram.
Figure 2.
Fishbone diagram .
ause and effect analysis diagra.
Ali Mustofa/ Reducing Sorting and Return of Sauce Packed Products As a Green Production Strategy In Flexible Packaging Industry Kreator Vol.
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Based on Figure 2 above, from a machine perspective, the use of air shafts causes unstable roll flatness on the rewind shaft during grooving.
This type of shaft operates by simultaneously locking the paper core using a pressurized air cylinder mechanism along the surface of the shaft.
Figure 3.
Air shaft type with air tube mechanism and single model paper core clamp From the material factor, the condition of the paper core that is defective .
hange in inner diamete.
causes the problem of narrow paper core in Sauce Pack products.
Narrow paper core occurs due to the use of ineffective core plugs, improper handling and high mobility of the goods.
Core plugs are pads in the form of plastic rings placed on both sides of the FG which are useful to protect the paper core from damage during handling activities .
hen the FG packaging is produced, the FG storage in the warehouse until the FG delivery to the custome.
Figure 4.
Narrow paper core problem with core plug on the side Figure 5.
Existing core plug .
efore repai.
Based on the results of the fishbone analysis above, the next step is to determine the improvement targets .
efore and after improvement.
Tabel 4.
Determining Improvement Targets Improvement (Depending on the size Prerequisites Target to be achieved Sorting 113 rolls of Untidy Rolled Sauce Pack products in the Slitting process and Returning narrow paper core problems totaling 21 rolls during the period January 2025 to April 2025.
Reduce sorting of Messy Roll Sauce Pack products in the Splitting process to an average of 8 rolls per month and 0 rolls of narrow paper core issues returned on Sauce Pack products for the period May 2025 to September 2025 Overview of Targets Based on SMART Elements Specific Reducing the Problem of Sorting Untidy Gaps on Topact Sauce Pack Products in the Splitting Process and Eliminating Narrow Return Paper Cores on Sauce Pack Products Measureable Reduce the problem of messy roll stacking by 50% from an average of 18 rolls per month and reduce the problem of narrow paper core returns from 21 rolls to 0 rolls in line with the Zero return management target.
Achievable Based on the analysis to be conducted, it shows that the target of achieving an average of 8 rolls of Untidy Roll Sorting and 0 rolls of narrow paper core problem returns within a three-month period is realistic and can be achieved through several improvements in the slitting process.
Reasonable Based on the nature of the problem, the messy roll and narrow paper core problem does not occur on all rolls because the problem is influenced by, among other things, the thickness and packaging treatment as well as the delivery time.
Time Base The impact of the repair will affect: .
f there is an impact, mark (E.
, there can be more than one impac.
Target achieved May to September 2025 Oo Oo Oo Q: Quality C: Cost Efficiency D: Delivery (Shipping.
Kreator P-ISSN: 2354-9505 E-ISSN : 2548-9542 Others (Specif.
Oo Oo Oo Productivity Safety Environment Moral Kreator Vol.
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Based on table 4 above, the target to be achieved is to reduce the problem of messy roll separation on Sauce Pack products to an average of 8 rolls per month and 0 returns of narrow paper core problem rolls on Sauce Pack products in the period May 2025 to September 2025.
The next step is to determine an improvement plan using 5W 1H analysis.
Tabel 5.
Determination of Repair Plan What Why How Where Problem Solution Reason Detail Activity Location The main structure of the air shaft type rewinder is an air cylinder tube with a plate strip as an Replacing the air shaft type winding shaft with a friction ring The flatness of the roll is unstable during the cutting process on the rewinder axle.
Conducted tests using shaft friction rings on sauce pack product process for 20 days Slitting Machne The inner surface of the Paper Core is Change the diameter of the Core Plug to a more ideal Finding materials for core plugs The inner edge of the Paper Core is damaged (Paper Core E.
Existing core plug materials are not strong enough to withstand impact.
Conduct observations on the most ideal outer diameter of the Core Plug without disrupting the functional use of the core plug.
Conduct core plug quality testing with vertical and horizontal FG drop Whe Whe May Who How Much Who Cost Spv and Operator Downtime Rewinder Axle Replacement Rp.
462,852
or 1 hou.
Lathe Machine Electricity Cost Rp.
50,000 (Rp.
10,000/hour x 5 Hour.
Slitting Dept May Slitting Dept Slitting Dept May Slitting Dept After determining the repair plan, the next step is to carry out repair activities according to the determined solutions.
Tabel 6.
Repair Activities for Loose Coil and Narrow Core Plug Problems Aspect Before the repair After repair Using the Air shaft .
nstable tension, messy visual zigzag Using a Sliding Ring type shaft .
ore stable tension, neat and accurate windin.
Sorting dropped from 18 rolls per month to 7 rolls per month, or a decrease of 72.
Shaft Type Using PP/LLDPE material .
ragile and easily broke.
Using ABS material .
turdy, not easily broke.
Rework costs of IDR 13.
million and potential loss of sales of IDR 216 million Rework costs of IDR 4.
million and potential loss of sales of IDR 21 million Core plug Cost Saving Effect There was no change in the inner diameter of the paper core with FG drop tests vertically and horizontally.
Total cost savings of 236 million over 3 Based on the data in Table 6 above, the use of the friction ring shaft type has an impact on the quality of the resulting rolls, with the sorting problem decreasing from 18 rolls to 7 rolls per month, a decrease of 72.
Furthermore, the use of ABS material in the core plug has significantly improved the condition of the inner diameter of the paper core, preventing defects or deformation.
Table 7 shows the activity of selecting core plugs to replace existing core plugs from existing waste .
erived from Ex Ordinary Film Raw Material.
by conducting FG drop tests vertically .
eight Ali Mustofa/ Reducing Sorting and Return of Sauce Packed Products As a Green Production Strategy In Flexible Packaging Industry Kreator Vol.
No.
2 Tahun 2025, pp.
approximately 100 c.
and horizontally .
eight approximately 50 c.
, with each test frequency .
ertical and horizonta.
5 times.
Tabel 7.
Core Plug Selection Activity .
erived from Common Film Raw Material.
No.
Core Plug Ex RM Film Supplier Inner Diameter .
Jisung
151,45
Material PP/ HDPE
RM Film
Weight
Inamulti PP/ HDPE
Kencar
PP/ HDPE
SRF
PP/ HDPE
Indopoly ABS Mnus Surplus Lightweight, easy to The shape is not symmetrical/sometimes oval, the inner diameter of the core plug is smaller The surface of the ear is irregular/tends to be Very strong, constant inner diameter size Serrated .
errated 7 m.
Based on the activity data in Table 7.
ABS core plugs have better advantages than others, namely the ability to withstand loads of up to 2 tons and a constant inner diameter.
The next step is to modify the dimensions of the ABS core plug to match the dimensions of the existing core plug using a lathe.
Figure 6.
Activity of making ABS core plugs from Ex RM Plain Film using a lathe Figure 7.
FG Vertical and Horizontal Drop Resistance Test Activity After conducting the vertical and horizontal FG drop tests, the inner diameter of the paper core was checked using a gonogo .
tool for measuring the diameter of holes made of nylo.
The test results found that there was no defect or deformation in the paper core.
CONCLUSION
Based on the results of the improvements made, two dominant factors were the main cause of the problem of messy roll separation and the problem of narrow paper core return, namely the old type rewinder system .
that could not maintain tension stability, as well as the type of core plug material that was less strong than ideal.
Both conditions caused visual and mechanical defects in the final FG results so that the product was sorted and returned by the customer.
From the test results, it was found that the use of the friction ring type shaft successfully reduced sorting from 18 rolls per month to 7 rolls per month, or a decrease of 72.
2%, and also the use of ABS material on Kreator P-ISSN: 2354-9505 E-ISSN : 2548-9542 Kreator Vol.
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the core plug had a significant impact on the condition of the inner diameter of the paper core where the inner diameter of the paper core did not experience any defects or defects.
REFERENCES