Application of Quality Function Deployment in Orthodox

7/25/2019 Application of Quality Function Deployment in Orthodox

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APPLICATION OF QUALITY FUNCTION DEPLOYMENT IN ORTHODOX

BLACK TEA INDUSTRY IN INDONESIA1)Rohayati SuprihatiniIndonesian Tea and Cinchona Research Institute

Gambung PO Box 1013 Bandung !0010 Phone" #0$$% &'$(1(& &'$()($ *acs+" #0$$% &'$(1(,

-.mai/" gambungbdg+centrin+net+id

1%rtic/e in bahasa Indonesia has been pub/ished in 2urna/ Penga4ian

dan Pengembangan Teno/ogi Pertanian 5o/+ ( 6o+ 3 $00& p+

!$,.!3&+

ABSTRACTIndonesian tea maret experienced a decrease in the 7or/d tea

export 8rom 10+39 in 1''3 to ,+!9 in $003 due to the :ua/ity

prob/em+ study aimed to identi8y current position o8 the

Indonesian orthodox b/ac tea :ua/ity and main e88orts to increase

the satis8action /e;e/ o8 the Indonesian tea buyers+ The


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not been 8u//y met the maret taste+ Inagreement 7ith the

tea :ua/ity 7as particu/ar/y on the inagreement 7ith the

organo/eptic grade and :ua/ity #taste aroma and co/or%

as re:uired by the buyers+ This had increased the unso/d

tea in the 2T+ To increase satis8action o8 the Indonesian

tea buyers there8ore impro;ement o8 the Indonesian tea

:ua/ity must be done to meet the maret desire through

app/ication o8 the er o8 the 2T+

In8ormation 7as co//ected to impro;e satis8actions o8

the Indonesian tea buyers through discussions 7ith 8i;e

experts in tea processing consisting o8 t7o researchers

8rom the Indonesian Tea and Cinchona Research Institute

Bandung and three tea p/antation super;isors o8 the PT

Perebunan 6usantara 5III est 2a;a and t7o tea tasters+The inter;ie7s 7ere re/ated to re/ationship bet7een each

attribute o8 tea :ua/ity and steps in the tea production

processes+ The Sri ?anan tea 7as used as comparison

#contro/% 8or the Indonesian tea because the tea production

system in Sri ?ana is simi/ar to that in Indonesia

particu/ar/y on the c/imate soi/ tea c/one genera//y used

#TRI $0$&% and most/y produced in the 8orm o8 b/ac tea

using an orthodox #con;entiona/% system+


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Data Aal!"i"

eight measuring method in each tea attribute 7hich is

a/so used to se/ect the consumersF expectation attributes

o8 the tea product 7as done by the method o8 -icenrode

#DaFari8 and Tan4ung $003% using the 8o//o7ing steps"

1+ Respondents 7ere ased to ran a// the criteria+ In this

study case the criteria used 7ere tea grade per8ormance o8 dry tea partic/es taste and aroma o8 tea

mix pacaging materia/ used as 7e// as product de/i;ery

and payment system+

$+ Preparing a tab/e such as sho7n in Tab/e 1+

eight ca/cu/ation #B1H++Bn% 7as done using the

8o//o7ing e:uation"

n

6i J 2ri4 K Rn.1

41

m

Tota/ ;a/ue J 6i

I1A1+++Am expectation attribute o8 customer #Tab/e $%

Bi 6iLtota/ ;a/ue

6i ;a/ue o8 the ith criterion

2ri4 number o8 respondents 7ho chose the 4 th ran

8or the ith criterion

2r3$ number o8 respondents 7ho chose the $nd ran

#R$% 8or the 3rd criterion #A3%

Rn.1 times or 8o/ding 8actor


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Tab/e 1+ Tabu/ation method o8 -icenrode+

Criteria Raning number 5a/ue eight

R1 R$ R3 H++ Rn

A1 2r11 2r1$ 213 H++ 2r1n 61 B1

A$ 2r$1 2r$$ 2r$3 H++ 2r$n 6$ B$

A3 2r31 2r3$ 2r33 H++ 2r3n 63 B3

H++ H+ H+ H+ H++ H++ H+ H+

Am 2rm1 2rm$ 2rm3 H++ 2rmn 6n Bn*o/ding 8actor Rn.1 Rn.$ Rn.3 H++ Rn.n Tota/ ;a/ue 1+00

Source" DaFari8 and Tan4ung #$003%+

30 Rohayati Suprihatini

gi;en a measure to determine its e88ect on the product

:ua/ity+

!+ To compare per8ormances+ This step 7as done to

compare the per8ormance o8 the company and its

competitor+ The grades used 8or the per8ormances 7ere

& 8or the best and 1 8or the 7orst+ *or examp/es the

best grade #&% is used 8or tea partic/e 7ith b/acish co/or

and the 7orst #1% is 8or tea partic/e 7ith grayish co/or+

&+ To e;a/uate customers to compare their opinions on:ua/ity o8 tea product o8 a company and its competitor+

The grades used in this test 7ere 1 to &M a ratio 7as

then made bet7een the target and each category+

,+ To determine e88ects o8 re/ationship bet7een acti;ities

in the tea processing or one resource 7ith another+

Datrix o8 Eouse o8


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tea Crushing Tearing and Cur/ing #CTC% amounting to

119 #Internationa/ Tea Committee $003%+

Ho#"e Q#alit! o* t+e I,oe"ia O%t+o,o'

Blac- Tea

Datrixes o8 the EO< 7ere the most 7e// no7n 8orm o8 the

e the ed according to the maret demand+

s an i//ustration the composition o8 the tea product 8rom

Sri ?ana in $001 7as dominated by the /o7 gro7n tea

type #&$.&,9% 7hi/e the rest 7ere consisted o8 the high

gro7n type #$).$'9% and medium gro7n type #1(.1'9%

#Tab/e 3M APB.PTP6 1.NI5 $001%+ On the other hand

composition o8 the Indonesian tea product 7as dominated


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by the medium gro7n type #&09% and the rest 7as

composed o8 /o7 gro7n #309% and high gro7n #$09%

types respecti;e/y+1 . tea "+oot"/ 0 . it+e%i2 (%oce""/ 3 . %olli2 (%oce""/ 4 . $illi2 (%oce""/ 5 . et "o%tatio (%oce""/ 6 . e7!$atic o'i,atio (%oce""/ 8 . ,%!i2

(%oce""/

9 . ,%! "o%tatio (%oce""/ : . (ac-i2 (%oce""/ 1; . "to%a2e (%oce""/ 11. $a%-eti2 acti> . (o"itiymatic oxidation

process drying and pacing processes and storing

process+

*urther discussion 7as 8ocused on e88orts to impro;e

shoot tip :ua/ity and ro//ing and mi//ing processes in the

program 8or impro;ement o8 the production process raned

8irst and third priorities respecti;e/y+ In re/ation to

impro;ement o8 tea shoot :ua/ity The Indonesian Tea andCinchona Research Institute #Pusat Pene/itian Teh dan Aina

1''!% reported that the :ua/ity o8 dry tea is ;ery much

dependent on the :ua/ity and hand/ing o8 the dry shoot

during picing in the co//ection p/ace in the containment

and during transport to the 8actory+ good tea picing

type is medium purity 7ith resu/ts o8 shoot ana/ysis reached

minimum ,&9 8ine+ Genera//y the type o8 tea picing in


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Indonesian p/antations sti// used the medium pic 7ith

shoot ana/ysis bet7een &0.,09 hence the picing :ua/ity

needs impro;ement+ On the other hand the shoot hand/ing

has not been obser;ed critica//y so that the 8reshness

8rom picing ti// ready 8or processing in the 8actory needs

to be impro;ed simu/taneous/y 7ith the shoot picing

:ua/ity+

Dahanta et a/+ #1''0% studied the e88ect o8 shoot picing

and processing on :ua/ity o8 the Indian b/ac tea+ The

rough picing standard 7as corre/ated to the high 8iber

content and causing the /o7 tea :ua/ity+ On the other hand

the smooth picing standard increased the amount o8

so/ub/e compound hence impro;ed the tea :ua/ity+

O7uor and Othieno #1'((% a/so reported e88ect o8 postpicing period on b/ac tea :ua/ity in Aenya+ Some

postpicing 8actors in8/uencing the tea :ua/ity 7ere shoot

hand/ing and transportation inc/uding picer picing

baset transport to shoot co//ection p/ace techni:ue and

condition o8 7eighing and transport to the 8actory+Resu/ts o8 discussions 7ith 8i;e tea processing

specia/ists and t7o tea tasters indicated that the conditions

o8 the shoots had a strong positi;e corre/ation 7ith other

processing steps inc/uding 7ithering ro//ing mi//ing 7et

sortation en>ymatic oxidation dry sortation pacaging

and mareting+ The ra7 materia/ o8 8resh shoots #picing

and hand/ing :ua/ities% 7as the main 8actor in the tea

:ua/ity+

Resu/ts o8 discussions 7ith p/antation managers

indicated that basic strategy on tea picing in each

p/antation 7as ;aried and ;ery much dependent on the

management strategy 7hether the tea production is

8ocused 8or production o8 high :ua/ity tea or on/y 8or

medium :ua/ity tea+ The tea picing strategies in most

Indonesian tea p/antations 7ere genera//y done to eep a

ba/ance bet7een :ua/ity and :uantity so that most o8 the

Indonesian tea products 7ere in the category o8 medium

:ua/ity+

In re/ation to the :ua/ity impro;ement =eming #1'(,%

mentioned the ro/e o8 product :ua/ity impro;ement in the

company per8ormance+ In this case the :ua/ity 7as

designed and produced to 8u/8i// the customersF demand+

product has a good :ua/ity 7hen it meets the customersFneed can be used proper/y and is produced using a good

and proper techni:ues+ The :ua/ity impro;ement 7i//

reduce reprocessing cost /e;e/ o8 mistaes and s/o7ness

so that the producti;ity cou/d be increased+ The

impro;ement in :ua/ity and reduce in cost 7i// increase

maret occupation and bussiness and 8ina//y absorb /abors

and increase more return o8 in;estment+

Ao/ari #1''&% a/so stressed on e88ort to impro;e


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product :ua/ity 7hich 7as sho7n by impro;ing product

per8ormance reducing cost and increasing precision in

time o8 trans8er+ The decrease in reprocessing cost o8 tea is

particu/ar/y in cost reduction during sortation o8 dry tea to

remo;e the sta/y and 8ibrous materia/s+

The ro/e o8 :ua/ity impro;ement 7as a/so stated by

Gasper> #1'')%+ *u// attention on :ua/ity impro;ement

resu/ted in positi;e impacts to the company at /east in t7o

7ays i+e+ #1% impact on production cost and #$% impact

on income return+ The impact on production cost 7as

gained 8rom de;e/opment o8 product that has high /e;e/ o8

agreement 7ith the standard thus 8ree 8rom possib/e

damages or physica/ de8ects+ Eence the production

processes that pay attention on :ua/ity 7i// produce

:ua/i8ied high :ua/ity product that 8ree 8rom damages+ This

7i// pre;ent 8rom 7asting and ine88iciency hence the

production cost per unit product becomes /o7er and 8ina//y

resu/ts in more competiti;e products+The impact on increase in return income occurred

through increase in se//ing o8 high :ua/ity product 7ith

competiti;e prices+ The high :ua/ity products 7i// ha;e

some specia/ties that enab/e to impro;e the consumersF

satis8action in using the particu/ar product+ -;ery

consumers 7i// maximi>e their satis8action in consuming

the product hence on/y the high :ua/ity product 7ith

competiti;e price 7i// be chosen by the consumers+ This

condition enab/e to increase se//ing or trading the product

and thus 7i// impro;e the maret segments and 8ina//y the

companyFs income+

*urther ana/ysis 7as done in re/ation to the

impro;ement o8 ro//ing and mi//ing in the tea processing+

Basica//y these processes are e88orts to mae the best

physica/ condition 8or reaction o8 the oxydase en>yme and

the po/ypheno/+ Chemica/ changes that occur during ro//ing

are the starting point o8 oxydation process that produce

bro7n co/or and speci8ic aroma+ Chemica//y the reaction

bet7een po/ypheno/ and the po/ypheno/ oxydase is due

to the presence o8 oxygen and as a base 8or the 8ormation

pp/ication o8 :ua/ity 8unction dep/oyment in orthodox b/ac tea +++ 33

o8 inner :ua/ity o8 the tea+ The tea ro//ing bruised the /ea;es

and damaged the ce// 7a//s and the ce// /i:uid came oute;en/y to the sur8ace and by this time en>ymatic oxidations

occurred+ The ro//ing he/ps the mi//ing process easier+

bbas et a/+ #1'''% reported that resu/ts o8 the ro//ing

and mi//ing processes 7ere in8/uenced by pressure on the

materia/ #7ithered shoots% speed o8 the ro//ing cy/inder as

7e// as ro//ing and mi//ing times+ Contro//ing these 8actors

enab/e to manage po7der :ua/ity o8 the tea

mong the ob4ecti;es o8 the mi//ing are" #1% to mae


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the si>e o8 the tea ro// sma//er to meet the customersF

re:uirementsM #$% to cut the ro// si>e shorterM #3% to s:uee>eL

grind shoots in order the ce// /i:uid to come out maxima//y

and to obtain more cur/ed dried productM and #!% to obtain

as much as 7et po7der+ Criteria 8or the success o8 ro//ing

and mi//ing besides the chemica/ properties reached a/so

obtain much 7et po7der+ Besides the ro//ing /oss is sti// in

a proper /imit 7hich is about 0+&.!+09+

In re/ation to the use o8 mi//ing program using an

orthodox rotor;ane Bambang et a/+ #1''1% reported that

three time mi//ing using a rotor;ane 7as not recommended

because the dried tea resu/ted has reddish co/or bitter

taste and the tea mix is dar a/though its strength is

signi8icant+ The use o8 the rotor;ane increases the amount

o8 7et po7der obtained+ It is suggested there8ore that

the use o8 the rotor;ane is done as ear/y as possib/e #R5 $.

3% to obtain high percentage o8 the prime tea+

Resu/ts o8 discussion 7ith 8i;e tea processingspecia/ists and t7o tea tasters sho7ed that ro//ing and

mi//ing processes had strong positi;e corre/ation 7ith some

other processes such as 7ithering 7et sortation

en>ymatic oxydation drying dry sortation pacaging and

re8inement /e;e/ o8 the ra7 materia/ o8 shoots used+

There8ore impro;ements o8 the ro//ing and mi//ing 7i//

increase the per8ormance o8 other re/ated next steps+

CONCLUSION

mong a// the consumersF expectation attributes the

orthodox b/ac tea 8rom Indonesia 7as a/7ays /o7er than

that 8rom Sri ?ana except the pacaging attribute and

c/aim 8inishing ser;ice that ha;e been done appropriate/y+

Impro;ement o8 Indonesian tea type and grade attributes

to meet the customersF expectation must be the main

priority+ In this case the type and grade o88ered by Sri

?ana through the Co/ombo Tea uction #CT% 7ere

considered near/y idea/+ Composition o8 the tea product

8rom Sri ?ana 7as dominated by the /o7 gro7n type #&$.

&,9% 8o//o7ed by high gro7n type #$).$'9% and medium

gro7n type #1(.1'9%+

Some technica/ aspects o8 tea processing need urgent

impro;ement in an e88ort to increase satis8actions o8 the

Indonesian tea buyers+ Priorities need to be done basedon the rans as 8o//o7" #1% impro;ement o8 tea shoot :ua/ityM

#$% impro;ement o8 mi//ing processM #3% impro;ement o8

ro//ing processM #!% impro;ement o8 7ithering processM #&%

impro;ement o8 7et sortation dry sortation and mareting

acti;itiesM #,% impro;ement o8 en>ymatic oxydationM #)%

impro;ement o8 drying and pacing process and #(%

impro;ement o8 storing process+ Some e88orts need to be

done to impro;e shoot :ua/ity such as #1% picing :ua/ity


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#minimum ,&9 re8ined shoots%M #$% hand/ing and transport

o8 tea shoots 8rom picing p/acing in the container #baset%

transport to the co//ector condition and method o8 shoot

7eighing unti/ transport to the 8actory and #3% hand/ing o8

the tea shoots in the 8actory prior to the 7ithering process+

REFERENCESbas T+ A+ Bambang D+ Son4aya dan 2+ Pitoyo+ 1'''+ Rancang

bangun pengenda/i sistem pengo/ahan teh hitam+ Daa/ah

Seminar -;a/uasi Easi/ Pene/itianLPereayasaan /sintan+

Bogor ,.) pri/ 1'''+

Bambang A+ Sugiarto dan + Purnama+ 1''1+ Pengo/ahan teh

hitam ombinasi orthodox.rotor;ane #III% Penggunaan

rotor;ane tiga a/i /e7at dengan berbagai ;ariasi peneanan

p/at u4ung+ Bu/etin Pene/itian Teh dan Aina L!%" (&.',+

=eming +-+ 1'(,+ Out o8 Crisis+ DIT Center 8or d;anced

-ngineering Study Cambridge A+

Gasper> 5+ 1'')+ Dana4emen Aua/itas+ Penerapan Aonsep.onsep

Aua/itas da/am Dana4emen Bisnis Tota/+ Qayasan Indonesia

-mas and PT Gramedia Pustaa tama 2aarta+

Internationa/ Tea Committee+ $003+ nnua/ Bu//etin o8 Statistics

$003+ Internationa/ Tea Committee ?ondon+Ao/ari +2+ 1''&+ Creating aria and S+ Baruah+ 1''0+ In8/uence o8

picing and processing on ce// 7a// and so/ub/e components in

the b/ac tea+ T7o and Bud 3)#1%" 1).1'+

Darimin dan E+ Duspita7ati+ $00$+ Aa4ian strategi peningatan

ua/itas produ industri sayuran segar #Studi asus di sebuah

agroindustri sayuran segar%+ 2+ Teno/ogi Industri Pangan

NIII#3%" $$!.$33+

O7uor P+O+ and C+O+ Othieno+ 1'((+ *actors a88ecting tea :ua/ity"

Posthar;est ;ariab/es+ re;ie7+ Tea '#$%" (&.'3+

Parsaei E+R+ and +G+ Su//i;an+ 1''3+ Concurrent -ngineering"

Contemporary Issues and Dodern =esign Too/s+ Chapman and

Ea// ?ondon+

Pusat Pene/itian Teh dan Aina+ 1''!+ Petun4u Tenis Pengo/ahan

Teh+ Pusat Pene/itian Teh dan Aina Gambung Bandung+

Sadono D+ G+T+ Du/yati dan + Pur7anto+ $000+ Imp/ementasi

onsep

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Application of Quality Function Deployment in Orthodox