Competency mapping to develop human resources for Indonesia’s sugarcane agroindustry in the Industry 4.0 era

Figures & data

Table 1. DigComp 2.0 framework for five digital skill areas.

Dimension 1	Dimension 2
1. Information and data literacy	1. Browse, search and filter data 2. Evaluate data, information and digital content 3. Manage data, information and digital content
2. Communication and collaboration	1. Interact, share and collaborate through digital technology 2. Citizenship through digital technology 3. Netiquette 4. Digital identity management
3. Digital content creation	1. Digital content development 2. Integrate and repurpose digital content 3. Copyright and licences 4. Programming
4. Safety and security	1. Protecting the unit 2. Protection of personal data 3. Protect health and well-being 4. Protecting the environment
5. Problem solving	1. Solving technical problems 2. Identify technology needs and answers 3. Creative use of digital technology 4. Identify digital skills gaps

Source: Vuorikari et al. (2016).

Figure 1. Research Methods.

Figure 2. Stages of research into recommendations for cane sugar production processes requiring new technology.

Table 2. Alternative for cane sugar production process.

No	Alternative cane sugar production processes
1.	Cut load transport
2.	Milling
3.	Refining
4.	Evaporation
5.	Crystallisation
6.	Separation
7.	Completion

Table 3. Criteria level of importance and negation of level of importance.

Criteria affecting yield	Expert-1		Expert-2		Expert-3		Average	Expert judgement	Negation of expert judgement
1. Number of losses	VH	4	VH	4	P	5	5	VH	A
2. Waiting time	P	5	P	5	VH	4	5	P	L
3. Distance from – to	A	2	VH	4	VH	4	4	H	H
4. Sugar cane hygiene	VH	4	VH	4	VH	4	4	VH	A
5. Machine malfunction	P	5	L	1	P	5	3	VH	A
6. Minimum quantity of sugarcane per day according to milling capacity	P	5	L	1	VH	4	3	A	VH

Table 4. Results of the expert assessment of alternative cane sugar production processes.

Expert	Alternative	Evaluation criteria
		1	2	3	4	5	6
Expert 1	1. Cut-load-transport	H	H	L	H	P	P
	2. Mill	P	VH	L	VH	P	VH
	3. Refining	P	P	L	VH	P	VH
	4. Evaporation	VH	VH	L	VH	P	VH
	5. Crystallisation	P	H	L	L	P	H
	6. Separation	A	VH	L	VH	P	A
	7. Completion	L	L	L	L	P	L
Expert 2	1. Cut-load-transport	A	VH	A	L	L	L
	2. Mill	L	L	L	L	L	L
	3. Refining	A	L	A	H	L	A
	4. Evaporation	L	L	L	H	L	A
	5. Crystallisation	P	P	L	VH	L	H
	6. Separation	H	H	A	H	A	A
	7. Completion	H	A	A	L	L	L
Expert 3	1. Cut-load-transport	P	VH	VH	P	P	VH
	2. Mill	P	P	VH	VH	P	P
	3. Refining	P	VH	VH	VH	P	VH
	4. Evaporation	P	VH	VH	VH	P	VH
	5. Crystallisation	P	VH	VH	VH	P	VH
	6. Separation	P	VH	VH	VH	P	VH
	7. Completion	P	VH	VH	VH	P	VH

Figure 3. Diagram of final judgement by experts on production process technologies that require new technologies.

Figure 4. Technological prioritisation of cane sugar production in Indonesia, which requires new technologies.

Table 5. Comparison of sugar production process evaluation results with 2 (two) methods.

Aspects	Subject of research
	Sugar mills in Eastern Indonesia	Sugar mills in western Indonesia
Number of respondents	3 experts from 1 sugar mills	34 experts from 34 sugar mills
Methods	Non-numerik MEMCDM	Numerical decision making (Ms Excel)
Results	Category H (High): Cut-load-transport Milling Refining Evaporation Category A (medium): Crystallisation Separation Completion	Priority order: Cut-load-transport Crystallisation Refining Milling Completion Evaporation Separation

Table 6. Competency unit mapping.

Main objective	Key function	Main function	Basic function
Processing of sugar cane into white crystal sugar in accordance with the Indonesian national standard	Dept. QA – QC	Quality control of raw materials, process materials, process materials and finished products	Clean of the test laboratory *
			Clean up chemical spills *
			Maintain the working environment of analytical instruments *
			Maintain analytical balance *
			Prepare reagent solution according to procedure (daily)*
			Prepare standard solutions according to procedures (daily)*
			Store chemicals safely *
			Dispose of reagent waste in accordance with procedure *
			Take samples from sample points*
			Take a test sample/subsample of the sample at the point of sampling *
			Filing of samples *
			Prepare samples for chemical analysis *
			Perform conventional titrimetry analysis in accordance with procedure *
			Performance of titrimetric analysis in non-aqueous media in accordance with procedures *
			Performance of conventional gravimetric analysis in accordance with procedure *
			Performance of conventional gravimetric analysis in accordance with procedure *
			Performance of spectrophotometric analysis in accordance with procedures *
			Polarimeter operation in accordance with analysis requirements ***
			Operate refractometer in accordance with analysis requirements ***
			Operating the Dry Oven for moisture analysis ***
			Operate the Moisture Analyser ***
			Operate the pH meter ***
			Operate the Conductivity meter ***
			Perform colour analysis ***
			Perform CO2 content analysis ***
			Operate a bomb calorimeter for coal analysis ***
			Operate a coal grinder/crusher for sample preparation ***
			Perform turbidity analysis ***
			Perform particle size analysis on sugar products ***
			Make distilled water with a distiller ***
			Perform sediment analysis ***
			Perform colourimetric analysis according to the procedure *
			Calibrate of analytical balance(s)*
			Make Certificate of Analysis (CoA) products ***
		Control microbiological quality	Control of the microbiological quality ***
			Prepare seeding media for Microb *
			Carry out sterilisation process in accordance with procedure *
			Perform aseptic technique *
			Perform microbial inoculation and subculture *
			Perform pathogenic microbial analysis **
			Carry out room and equipment sanitising tests *
			Perform microbiological water quality testing *
			Perform microbiological sugar quality testing ***
			Operate the Laminer Airflow device ***
			Conduct total microbial determination by TPC **
		Conduct of supervision	Supervise sampling and analysis ***
			Write a report on the results of the analysis *
			Carry out interpersonal communication *
			Control the recording of analysed data *
			Verify of results Certificate of Analysis (CoA)***
		Carry out supervision and evaluation of laboratory performance	Ensure that products meet the required standards ***
			Make Monthly Report ***
			Review of the daily report in relation to the analysis results and plant performance ***
			Evaluation of process material and utility consumption rates in accordance with company standards ***
			Implement a work supervision system *
			Manage the ordering process for chemicals and laboratory equipment *
			Implement a process for repairing analytical instruments using third parties *
			Documentation of all quality control activities *
			Coordinate activities of Good Laboratory Practice (GLP)*
			Implementation of a work control system *
			Create a tool operating manual *
			Preparation of work instructions for chemical analysis *
			Evaluate the analysis results *
			Validate the analysis method * (Carry out Test Method Validation/Verification Following Procedure)
Determine the uncertainty value of the analysis *
Development of test methods *
Specify test methods for health and safety equipment (K-3) *
Evaluate sampling points ***
Perform laboratory work scheduling	Conduct analysis of workforce development ***
	Develop a laboratory work plan ***
	Develop a plan Developing a budget plan on a periodic basis ***
	Evaluate the performance of QC and QA personnel ***
	Define the roles and functions of laboratory staff *
	Plan the analytical quality control system *
	Verify product release ***
Department on the Cut-Load-Transport Section	Carry out work planning for cut-load-transport	Planning for cut-load-transport activities
		Coordinate the implementation of cut-load-transport activities
		Plan a budget for cut-load-transport activities
		Plan the target of cut-load-transport activities
	Organise cut-load-transport activities	Analyse cut-load-transport problems and their solutions
		Prepare a budget plan for cut-load-transport
		Set up targets for cut-load-transport activities
		Prepare a risk mitigation plan for cut-load-transport activities
		Coordinate cut-load-transport activities
		Evaluate cut-load-transport activities
	Organise cane delivery activities in each zone	Plan operator tasks and targets in each zone
		Control of farmer registration
		Control of farmer land mapping
		Control of administrative services for cane delivery by zones
		Conduct risk mitigation
	Carry out sugarcane delivery activities	Set up registration facilities
		Prepare farmer land mapping
		Communicate cane supply to farmers
	Organise sugarcane reception activities	Control of the budget requirements for sugar cane receipts
		Control of labour logistics activities
		Monitor the cane receiving system to ensure smooth operation
	Carry out sugarcane reception activities	Set up truck queue lanes
		Preparation of cane reception facilities at the inspection post and factory
		Organise the unloading of the sugar cane in accordance with the FIFO rules
	Timber harvesting management (title of cultivation rights)	Find workers to cut sugar cane
		Set up harvesting equipment
		Set up sugarcane transport
		Supervision of the cut-load-transport process in accordance with the standards
Dept. Production – Milling Department	Perform milling job planning	Create a milling production plan
		Perform division of labour
		Coordinate milling process implementation
		Evaluate the milling job plan
		Plan the budget to meet the needs for consumables and spare parts for the milling process
	Organise milling activities	Analyse and solve the problem ***
		Analysis of the milling process and the materials
		Determine the milling process and flow method
	Evaluate milling activities	Evaluate the parameters of the Tandem Mill, Cane Preparation according to the procedure
		Evaluate the unloading of sugar cane trucks according to sequence and production capacity, and check and repair the hydraulic tipping system in the Tipper Control Room according to procedure
		Assessment of the condition of the scraper (mini-excavator) in accordance with procedures
		Evaluate machinery (cutter, shredder, side cane carrier, main cane carrier) and cleanliness in the cane preparation area in the field according to procedures
		Field evaluation of the operation of milling machines, pumps, intermediate carriers, bagasse elevators in accordance with procedures
		Assessment of the condition of the existing lubricants, periodic replacement of the lubricants, cleaning of the residual grease on the tandem mill in accordance with the procedures
	Control milling activities	Control of the operation of the tandem mill, cane preparation machine
		Controlled sugar cane truck dumping operations according to sequence and production capacity, and checked and repaired the hydraulic tipping system in the Tipper Control Room
		Control operations of scrapper (mini excavator)
		Control of machine operation (cutter, shredder, side cane carrier, main cane carrier) and cleanliness in the cane preparation area in the field
		Control of the operation of the milling machines, the pumps, the intermediate carriers, the bagasse elevators in the field
		Assessment of the condition of the available lubricants, periodic replacement of lubricants, cleaning of residual grease on the tandem mill in accordance with procedures
	Operate tools in the milling section	Operate the Tandem Mill machine, Cane Preparation as well as checking the actual condition of the machine with virtual inspection and taking vibration, temperature data periodically in the Distribute Control System
		Check the actual condition of the tandem mill machine, cane preparation by virtual inspection and taking vibration, temperature data periodically in the field according to procedures
		Operate the sugarcane dumping truck in accordance with the sequence, production capacity and check and repair the hydraulic tipper system in the Tipper Control Room in accordance with procedures
		Check the condition of the available lubricant, change the lubricant drum, clean the remaining grease on the tandem mill in accordance with the procedure
		Clean of the rest of the sugar cane on the truck by means of a scraper (mini-excavator) in accordance with the procedure
		Monitor machinery (cutter, shredder, Side Cane Carrier, Main Cane Carrier) and cleanliness in the cane preparation area in the field in accordance with procedures
		Monitor of the milling machines, pumps, intermediate carriers and bagasse elevators in the field in accordance with the procedures
		Assessment of the condition of the available lubricants, periodic replacement of lubricants, cleaning of residual grease on the tandem mill in accordance with procedures
	Perform machine maintenance in the milling section	Disassembly, cleaning, inspection, repair and reassembly of cane preparation machines
		Disassembly, cleaning, inspection, repair and reassembly of intermediate support machines
		Disassemble, clean, inspect, repair and reassemble milling machines
		Coordination of machine maintenance issues in the grinding department with the engineering department related to the outside of the factory
Dept. Production – Process	Manage all production management	Create a working plan to produce ***
		Create a production schedule ***
		Coordinate the implementation of the production process ***
		Evaluate the production work plan ***
		Plan the budget to meet the needs of the consumables and spares process ***
	Organise production activities	Analyse and solve the problem ***
		Perform process and material analysis ***
		Determine process method and flow ***
	Control packaging activities	Evaluate bagging machine operations ***
		Ensure that bagging machine process parameters are according to procedures ***
		Identify finished product packaging ***
		Supervise subordinates ***
	Control of the operational activities of the centrifugal machines and the drying machines	Evaluate the operation of batch centrifuges ***
		Evaluate the operation of a continuous centrifuge ***
		Evaluate the operation of rotary dryers ***
		Evaluate the operation of the fluidised drying machine ***
		Ensure that the process parameters of the dryer are in accordance with procedures ***
	Control the crystallisation process	Evaluate the operation of the vacuum pan unit ***
		Ensure that the crystallisation process parameters are in accordance with the procedure ***
		Identify raw and auxiliary materials in the crystallisation process ***
	Control the purification process	Evaluate the operation of the carbonation machine ***
		Evaluate the operation of a filter press filtration machine ***
		Evaluate the operation of the filtration machine rotary leaf filter***
		Evaluate ion exchange resin unit operation ***
		Control of filter/strainer fine liquor***
		Evaluate the operation of the evaporator unit ***
		Control of filter/strainer thick liquor***
		Identify the composition of raw and auxiliary materials in the carbonation process. ***
	Control of the affination process	Evaluate the operation of a weighing weighing scale unit ***
		Evaluation of the operation of the mingler machine ***
		Evaluate the operation of affinity centrifuges ***
		Evaluate the operation of the screw affination machine ***
		Evaluate the operation of the affination smelter ***
		Ensure that affination parameters are in accordance with the procedure ***
		Identify raw and auxiliary affination materials ***
	Control activities packaging	Control bagging machine operations ***
		Control of the sewing machine operations ***
		Control of bagging machine process parameters in accordance with procedures ***
	Control the operation of centrifuges and dryers	Control of the operation of batch type centrifuges ***
		Control of the operation of a continuous centrifugal machine ***
		Control of the operation of the rotary dryer unit ***
		Control of the operation of the fluidised bed drying unit ***
	Process control Crystallisation	Control of evaporator operation ***
		Control of a thick liquor strainer/filter ***
		Control of vacuum pan operations ***
		Control of receiver tank operation ***
		Control of the use of raw materials and auxiliary materials used in the crystallisation process ***
	Control the process of Affinity	Control the operation of weighing units ***
		Control the mingler machine operations ***
		Control the operation of affination centrifuges ***
		Control the operations of the affination screw unit ***
		Control the operation of the carbonation unit ***
		Control the operation of the filter press filtration unit ***
		Control the operation of the rotary leaf filter filtration unit ***
		Control operations of ion exchange resin column***
		Control filter/strainer fine liquor***
	Operate tools in the bagging section	Operate the bagging machine ***
		Operate the sewing machine ***
	Operate tools in the drying section	Operate the rotary drying machine ***
		Operate the fluidised drying machine ***
	Operate tools in the centrifugation section	Operate batch-type centrifugal machines ***
		Operate continuous type centrifugal machine ***
	Operate tools in the crystallisation section	Operate the vacuum pan ***
		Control the tank receiver ***
Operate tools in the evaporation section	Operate the evaporator unit ***
	Operate a liquor filter/strainer ***
Operate tools in the decolourisation section	Operate the ion exchange resin machine ***
Operate tools in the purification section	Operate the carbonator unit ***
	Operate the filter press filtration machine ***
	Operate rotary leaf filter filtration machine ***
Operate tools in the affination section	Operate the mingler machine ***
	Operate the affination centrifuge ***
	Operate the screw affination machine ***
	Operate the melter machine ***

Notes:

*This is the basic function of the adoption of the Decree of the Minister of Manpower of the Republic of Indonesia No. 200 of 2016 on the Determination of Indonesian National Competency Standards for Professional, Scientific and Technical Services Category Principal Group of Other Professional, Scientific and Technical Services in the Field of Chemical Analysis.

**This is the basic function of the adoption of the Decree of the Minister of Manpower of the Republic of Indonesia No. 216 of 2017 on the Determination of the Indonesian National Work Competency Standards for the Category of Professional, Scientific and Technical Activities of the Principal Group of Architectural Activities and Engineering; Analysis and Technical Tests in the Field of Chemical Analysis Sub-sector of Bioassay and Analysis Related to Food Halal Safety.

***This is the basic function of the adoption of the Decree of the Minister of Manpower of the Republic of Indonesia No. 178 of 2020 on the Determination of the Indonesian National Work Competency Standards for the Processing Industry Category of the Food Industry Principal Group in the Refined Crystal Sugar Industry in the Quality Control and Production Sub-Sector (Ketenagakerjaan, 2020).

Table 7. List of cut-load-transport and milling units of competence.

No	Unit code	Title of competency unit
1.	C.10GKP00.001.1	Plan for cut-load-transport activities
2.	C.10GKP00.002.1	Coordination of the implementation of the cut-load-transport activities
3.	C.10GKP00.003.1	Plan of the budget for the activities of the cut-load-transport
4.	C.10GKP00.004.1	Plan the target of cut-load-transport activities
5.	C.10GKP00.005.1	Analyse cut-load-transport problems and their solutions
6.	C.10GKP00.006.1	Prepare the cut-load-transport budget plan
7.	C.10GKP00.007.1	Set up targets for cut-load-transport activities
8.	C.10GKP00.008.1	Prepare a risk mitigation plan for cut-load-transport activities
9.	C.10GKP00.009.1	Coordination of cut-load-transport activities
10.	C.10GKP00.010.1	Evaluate the cut-load-transport activities
11.	C.10GKP00.011.1	Plan operator tasks and targets for each zone
12.	C.10GKP00.012.1	Control of farmer registration
13.	C.10GKP00.013.1	Control of farmer land mapping
14.	C.10GKP00.014.1	Control of administrative services for cane delivery by zones
15.	C.10GKP00.015.1	Perform risk mitigation
16.	C.10GKP00.016.1	Set up registration facilities
17.	C.10GKP00.017.1	Prepare farmer land mapping
18.	C.10GKP00.018.1	Communicate sugarcane supply with farmers
19.	C.10GKP00.019.1	Control of cane revenue budget requirements
20.	C.10GKP00.020.1	Control of labour logistics activities
21.	C.10GKP00.021.1	Monitor the cane receiving system to ensure smooth operation
22.	C.10GKP00.022.1	Set up truck queue lanes
23.	C.10GKP00.023.1	Prepare the means of receiving sugarcane at the monitoring post and factory
24.	C.10GKP00.024.1	Organise the unloading of sugarcane in accordance with FIFO rules
25.	C.10GKP00.025.1	Find workers to cut sugar cane
26.	C.10GKP00.026.1	Prepare harvesting equipment
27.	C.10GKP00.027.1	Set up sugar cane transport
28.	C.10GKP00.028.1	Supervise the cut-load-transport process according to standards
29.	C.10GKP00.029.1	Create a milling production plan
30.	C.10GKP00.030.1	Perform division of labour
31.	C.10GKP00.031.1	Coordinate milling process implementation
32.	C.10GKP00.032.1	Evaluate the milling job plan
33.	C.10GKP00.033.1	Plan the budget to meet the needs for consumables and spare parts for the grinding process
34.	C.10GKP00.034.1	Analyse milling problems and their solutions
35.	C.10GKP00.035.1	Analyse the grinding process and materials
36.	C.10GKP00.037.1	Evaluate Tandem Mill, Cane Preparation parameters according to procedure
37.	C.10GKP00.038.1	Evaluate the unloading of sugar cane trucks according to sequence and production capacity, and check and repair the hydraulic tipping system in the Tipper Control Room according to procedure
38.	C.10GKP00.039.1	Evaluate the condition of the scraper (mini-excavator) according to the following procedures
39.	C.10GKP00.040.1	Evaluate machinery (cutter, shredder, side cane carrier, main cane carrier) and cleanliness in the cane preparation area in the field according to procedures.
40.	C.10GKP00.041.1	Evaluate the operation of milling machines, pumps, intermediate carriers, bagasse elevators in the field according to procedures.
41.	C.10GKP00.042.1	Evaluate the condition of existing lubricants, periodically replace lubricants, clean residual grease from the tandem mill according to procedures.
42.	C.10GKP00.043.1	Control of the operation of the tandem mill, cane preparation machine
43.	C.10GKP00.044.1	Control of the sugar cane truck dumping operations according to sequence and production capacity, and checked and repaired the hydraulic tipping system in the Tipper Control Room.
44.	C.10GKP00.045.1	Control of the operations scrapper (mini excavator)
45.	C.10GKP00.046.1	Control of machine operation (cutter, shredder, side cane carrier, main cane carrier) and cleanliness in the cane preparation area in the field.
46.	C.10GKP00.047.1	Control of the operation of milling machines, pumps, intermediate carriers, bagasse elevators in the field
47.	C.10GKP00.048.1	Operation of the tandem mill machine, cane preparation, as well as checking the actual condition of the machine with virtual inspection and recording vibration and temperature data periodically in the Distribute Control System
48.	C.10GKP00.049.1	Check the actual condition of the Tandem Mill machine, Cane Preparation by virtual inspection and taking vibration, temperature data periodically in the field in accordance with procedures
49.	C.10GKP00.050.1	Operate the sugar cane dump truck in accordance with the sequence and production capacity, and check and repair the hydraulic dump system in the dump truck control room in accordance with procedures
50.	C.10GKP00.051.1	Check the condition of the available lubricant, replace the lubricant drum, clean the remaining grease on the tandem mill according to the procedure
51.	C.10GKP00.052.1	Clean the remaining sugar cane on the truck using a scraper (mini-excavator) according to procedures.
52.	C.10GKP00.053.1	Monitor the machinery (cutter, shredder, side cane carrier, main cane carrier) and cleanliness of the cane preparation area in the field according to procedures.
53.	C.10GKP00.054.1	Monitor milling machines, pumps, intermediate carriers, bagasse elevators in the field according to procedures
54.	C.10GKP00.055.1	Disassemble, clean, inspection, repair and reassemble of cane preparation machines
55.	C.10GKP00.056.1	Disassemble, clean, inspection, repair and reassemble of intermediate support machines
56.	C.10GKP00.057.1	Disassemble, clean, inspect, repair and reassemble milling machines
57.	C.10GKP00.058.1	Coordination of machine maintenance issues in the grinding department with the engineering department related to the outside of the factory.

Vuorikari, R., Punie, Y., Carretero, S., & Van Den Brande, L. (2016). DigComp 2.0: The digital competence framework for citizens. JRC-IPTS, (June). https://doi.org/10.2791/11517

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Ketenagakerjaan, K. (2020). Keputusan Menteri Ketenagakerjaan RI No 178 Tahun 2020 Tentang Penetapan SKKNI Kategori Industri Pengolahan Golongan Pokok Industri Makanan Bidang Industri Gula Kristal Rafinasi.

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Data availability

The data that support the findings of this study are available on request from the corresponding author upon reasonable request.