Its all about lean manufacturing tools

1. General Information
Skill Matrix,
Multi Skill
Development
& Training Plan

2. General Information
Goal
Mampu membuat Skill
Matrix & Rencana Training

3. General Information
Coach’s Background
AJI WIJAYA KUSUMA, ST
Enthusiast & professional on Lean,
Improvement, people development
and motivation.
16 years experience in Apparel
Industry focus on practical lean
implementation, costing & capacity
management
471.wijayakusuma@gmail.com
+62 815 7898 6913
Aji Wijaya Kusuma
Lean Manufacturing
Industrial Engineering
Production Planning
Apparel CMT Costing & CPM
90%
90%
80%
85%
85%
Supplier Capacity Management
https://www.youtube.com/user/471WijayaKusuma/featured
https://www.facebook.com/Lets-LEAN-788239307962079

4. General Information
Masalah Pabrik
Garment

5. General Information
Layout
lama ± 1-2
hari Mesin
belum siap
pakai
Skill
operator
belum OK
Kalo sore
sisaan
permakan
masih ada

6. General Information
Training Within Industry
Perang Dunia Ke-2

7. General Information
Q1 Q2 Q3 Q4
1 2
2 5
3 6
4
1 1 2 2 2 2 1
GREENTEX LEAN DEPT-- SKILL MATRIX & TRAINING PLAN
SKILL NAME /PROCESS
1. Motion &
Time Study
4.
Presentation
3. 5S & Visual
Performance
7. Problem
Solving PDCA
2. Data
Analyze &
Visualization
5. Coaching 6. Inter Dept
Relation
REMARKS
ACTUAL CAPABILITIES
(75% PERFORMANCE)
Manpower Needs
Performance Needs
(Work Manner)
No.
Reni
5 6 7
Riski Chairani
NO SKILL
KNOW THE THEORY
CAN APPLY SOME OF THE THEORY
HAVE APPLIED IN MOST OF ACTUAL PROBLEM
CAN COACH OTHER WITH PROVEN RESULT
Winarsih
Putut Setiawan
Remarks
Job Needs
(Poduction Change)
RESULT OF
TRAINING
Beginning of Year
Middle of Year
End of Year
SKILL LEVEL
TARGET
LEAN TEAM NAME

8. General Information
Remarks
Job Needs
(Poduction Change)
End of Year
Middle of Year
RESULT OF
TRAINING
Beginning of Year
4
3 WATI
2 IKA
15
1 TINA
ACTUAL 10 3 2
6 52
6 2 5 3 5 3
TARGET TOTAL OPERATOR 10 5 5 2
No.
CAPABILITIES Manpower Needs
Q1 Q2 Q3 Q3
Performance Needs
(Work Manner)
JOIN
WB
CROSS
BOX
JOIN
HOOD
SNAP/BARTACK
PASANG
PLACKET
PASANG
ZIPPER
OVERDECK
MAKE
UP
OVERLOCK
SKILL MATRIX SEWING
Name:
Section/Group:
Date:
Process or
Operation
Name
PENGUASAAN MESIN PENGUASAAN PROSES SPESIAL
REMARKS
SINGLE
NEEDLE
DOIBLE
NEEDLE
TARGET SKILL
NAME

9. General Information
Creating a Planning Time-table
MULTI-FUNCTION WORKER TRAINING TIMETABLE
Name: REMARKS
Section/Group:
CAPABILITIES
Date:
NUMBER NAME
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
= 100% Performance
= 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks

10. General Information
MULTI-FUNCTION WORKER TRAINING SHEET
Name: Ron Coleman REMARKS
Section/Group:
CAPABILITIES
Date: 5/15/02 Jan Jun Dec
NUMBER NAME 4 6 6 6 6 6 6 6 4 4
1. Ron Coleman (Supervisor) 10 10
2. Eddie Day (Team Leader) 3 4
3. Jeffe Goedde (Team Leader) 3 5
4. Bradley Alvey 2 4
5. Tina Brooks 6 7
6. Clark Campbell 3 4
7. Willie Coleman 1 4
8. Dennis Daniel 1 2
9.
10.
3 3 3 1 3 3 2 3 5 3 = 100% Performance
5 4 4 2 4 4 3 4 6 4 = 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks
Frame Department
Forming
Grinding
Punching
Seam
Weld
Edge
Prep
Tacking
Spot
Weld
Flange
Weld
Paint
KEY
Increase orders 10% for the year
Primer
Step 1
Step 2

11. General Information
MULTI-FUNCTION WORKER TRAINING SHEET
Name: Ron Coleman REMARKS
Section/Group:
CAPABILITIES
Date: 5/15/02 Jan Jun Dec
NUMBER NAME 4 6 6 6 6 6 6 6 4 4
1. Ron Coleman (Supervisor) 10 10
2. Eddie Day (Team Leader) 3 4
3. Jeffe Goedde (Team Leader) 3 5
4. Bradley Alvey 2 4
5. Tina Brooks 6 7
6. Clark Campbell 3 4
7. Willie Coleman 1 4
8. Dennis Daniel 1 2
9.
10.
3 3 3 1 3 3 2 3 5 3 = 100% Performance
5 4 4 2 4 4 3 4 6 4 = 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks
Frame Department
Forming
Grinding
Punching
Seam
Weld
Edge
Prep
Tacking
Spot
Weld
Flange
Weld
Paint
KEY
Increase orders 10% for the year
Primer
Step 3
List Job
Names

12. General Information
1. Select Critical/Special Process/Machine
Line Style SKETCH Proses critical Jenis mesin OUTPUT QUALITAS Namaoperator NIK
Cross box Jarum 1 V V Saenur GIU0494
Obras pasangtangan Obras benang4 V Witri GIU2351
Obras variasi samping Obras benang4 V -
Tutup kerah Jarum 1 V V Khomsiyatun GIU2088
Stick armhole Kamput V V Drsini GIU0971
Cross box Jarum 1 V V Mila GIU3636
Hemmingtangan Kamput V -
Tutup kerah Jarum 1 V V Heni GIU0273
Cross box Jarum 1 V V Masriah GIU0277
Pasangkerah Jarum 1 V V Siti GIU1956
Stick slit Jarum 1 V V Biut GIU3783
Hemmingtangan Kamput V V Suhartiningsih GIU0758
Stick armhole /printing Kamput V Rohani GIU0290
Make up Make up V V Risna GIU0354
Obras kerah Obras benang4 V V Nuraini GIU0337
Stick zipper Jarum 1 V V iis GIU0210
Tutup kerah Jarum 1 V V Elis GIU4130
Pasangzipper Jarum 1 V V Mimin GIU0217
Pasangzipper Jarum 1 V V Uli GIU3204
Stick zipper Jarum 1 V V -
Corongtape kerah Jarum 1 V V -
Stick tape Jarum 1 V V -
Stick zipper Jarum 1 V V Kiswati GIU2461
8 385FA
395FA
2
395FA
12
7
5
P31142
MSTR08390
DATA CRITICAL PROSES SEWING
POLO
6
15
16

13. General Information
MULTI-FUNCTION WORKER TRAINING SHEET
Name: Ron Coleman REMARKS
Section/Group:
CAPABILITIES
Date: 5/15/02 Jan Jun Dec
NUMBER NAME 4 6 6 6 6 6 6 6 4 4
1. Ron Coleman (Supervisor) 10 10
2. Eddie Day (Team Leader) 3 4
3. Jeffe Goedde (Team Leader) 3 5
4. Bradley Alvey 2 4
5. Tina Brooks 6 7
6. Clark Campbell 3 4
7. Willie Coleman 1 4
8. Dennis Daniel 1 2
9.
10.
3 3 3 1 3 3 2 3 5 3 = 100% Performance
5 4 4 2 4 4 3 4 6 4 = 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks
Frame Department
Forming
Grinding
Punching
Seam
Weld
Edge
Prep
Tacking
Spot
Weld
Flange
Weld
Paint
KEY
Increase orders 10% for the year
Primer
Step 4
Assess Skill
Levels

14. General Information
SKILL
LEVEL
PERSENTASE
C 1%-25% Hanya dapat melakukan langkah-langkah dasar, dan masih belum lepas dari pengawasan
B 26%-50%
Dapat melakukan pekerjaan dengan aman, sesuai dengan kualitas yang diinginkan tapi
belum mencapai target waktu yang ditetapkan. Masih membutuhkan banyak pengawasan
S 76%-100%
Tidak membutuhkan pengawasan dan dapat melatih karyawan lain untuk melakukan proses
sewing yang ditargetkan
A 51%-75%
Dapat melakukan pekerjaan dengan aman, sesuai dengan kualitas yang diinginkan dan
mencapai target waktu yang ditetapkan. Hanya butuh sedikit pengawasan
SIMBOL KETERANGAN

15. General Information
MULTI-FUNCTION WORKER TRAINING SHEET
Name: Ron Coleman REMARKS
Section/Group:
CAPABILITIES
Date: 8/15/02 Jan Jun Dec
NUMBER NAME 4 6 6 6 6 6 6 6 4 4
1. Ron Coleman (Supervisor) 10 10
2. Eddie Day (Team Leader) 3 4
3. Jeffe Goedde (Team Leader) 3 5
4. Bradley Alvey 2 4
5. Tina Brooks 6 7
6. Clark Campbell 3 4
7. Willie Coleman 1 4
8. Dennis Daniel 1 2
9.
10.
3 3 3 1 3 3 2 3 5 3 = 100% Performance
5 4 4 2 4 4 3 4 6 4 = 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks
Frame Department
Chop
Saw
(2)
HPP
Glue
and
Dowel
Frame
Clamp
(2)
Prep/Inspect
Special
Busellato
Giben
Panel
Saw
Edgebander
KEY
Increase orders 10% for the year
Parts
Step 5
Ideal number: the ideal number
of people capable of doing the job
at 75% performance or better

16. General Information
MULTI-FUNCTION WORKER TRAINING SHEET
Name: Ron Coleman REMARKS
Section/Group:
CAPABILITIES
Date: 8/15/02 Jan Jun Dec
NUMBER NAME 4 6 6 6 6 6 6 6 4 4
1. Ron Coleman (Supervisor) 10 10
2. Eddie Day (Team Leader) 3 4
3. Jeffe Goedde (Team Leader) 3 5
4. Bradley Alvey 2 4
5. Tina Brooks 6 7
6. Clark Campbell 3 4
7. Willie Coleman 1 4
8. Dennis Daniel 1 2
9.
10.
3 3 3 1 3 3 2 3 5 3 = 100% Performance
5 4 4 2 4 4 3 4 6 4 = 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks
Frame Department
Chop
Saw
(2)
HPP
Glue
and
Dowel
Frame
Clamp
(2)
Prep/Inspect
Special
Busellato
Giben
Panel
Saw
Edgebander
KEY
Increase orders 10% for the year
Parts
Step 6
Step 6
Add Total
Capabilities

17. General Information
MULTI-FUNCTION WORKER TRAINING SHEET
Name: Ron Coleman REMARKS
Section/Group:
CAPABILITIES
Date: 8/15/02 Jan Jun Dec
NUMBER NAME 4 6 6 6 6 6 6 6 4 4
1. Ron Coleman (Supervisor) 10 10
2. Eddie Day (Team Leader) 3 4
3. Jeffe Goedde (Team Leader) 3 5
4. Bradley Alvey 2 4
5. Tina Brooks 6 7
6. Clark Campbell 3 4
7. Willie Coleman 1 4
8. Dennis Daniel 1 2
9.
10.
3 3 3 1 3 3 2 3 5 3 = 100% Performance
5 4 4 2 4 4 3 4 6 4 = 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks
Frame Department
Chop
Saw
(2)
HPP
Glue
and
Dowel
Frame
Clamp
(2)
Prep/Inspect
Special
Busellato
Giben
Panel
Saw
Edgebander
KEY
Increase orders 10% for the year
Parts
Performance needs:
• Individual adherence to quality, rate and safety standards
• Individual use of equipment and machines
• Waste, rework, damage to equipment and injuries
Step 8
Step 7
Manpower needs:
• New employees
• Promotions / transfers
• Vacations
• Temporary employees
• Job rotations
• Temporary assignments

18. General Information
MULTI-FUNCTION WORKER TRAINING SHEET
Name: Ron Coleman REMARKS
Section/Group:
CAPABILITIES
Date: 8/15/02 Jan Jun Dec
NUMBER NAME 4 6 6 6 6 6 6 6 4 4
1. Ron Coleman (Supervisor) 10 10
2. Eddie Day (Team Leader) 3 4
3. Jeffe Goedde (Team Leader) 3 5
4. Bradley Alvey 2 4
5. Tina Brooks 6 7
6. Clark Campbell 3 4
7. Willie Coleman 1 4
8. Dennis Daniel 1 2
9.
10.
3 3 3 1 3 3 2 3 5 3 = 100% Performance
5 4 4 2 4 4 3 4 6 4 = 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks
Frame Department
Chop
Saw
(2)
HPP
Glue
and
Dowel
Frame
Clamp
(2)
Prep/Inspect
Special
Busellato
Giben
Panel
Saw
Edgebander
KEY
Increase orders 10% for the year
Parts
Production needs:
• Work that piles up
• Seasonal work
• Bottlenecks
• New Work
• Production changes
Step 9

19. General Information
MULTI-FUNCTION WORKER TRAINING SHEET
Name: Ron Coleman REMARKS
Section/Group:
CAPABILITIES
Date: 8/15/02 Jan Jun Dec
NUMBER NAME 4 6 6 6 6 6 6 6 4 4
1. Ron Coleman (Supervisor) 10 10
2. Eddie Day (Team Leader) 3 4
3. Jeffe Goedde (Team Leader) 3 5
4. Bradley Alvey 2 4
5. Tina Brooks 6 7
6. Clark Campbell 3 4
7. Willie Coleman 1 4
8. Dennis Daniel 1 2
9.
10.
3 3 3 1 3 3 2 3 5 3 = 100% Performance
5 4 4 2 4 4 3 4 6 4 = 75% Performance
= 50% Performance
= In Training
Process or
Operation
Name
IDEAL NUMBER
Manpower Needs
Performance Needs
(Work Manner)
RESULT
OF
TRAINING
Beginning of Year
Middle of Year
End of Year
Job Needs
(Production Change)
Remarks
Frame Department
Chop
Saw
(2)
HPP
Glue
and
Dowel
Frame
Clamp
(2)
Prep/Inspect
Special
Busellato
Giben
Panel
Saw
Edgebander
KEY
Increase orders 10% for the year
Parts
Compare :
• IDEAL CAPACITY to
• RESULT OF TRAINING
Examine :
• Manpower Needs
• Capabilities and
• Job Needs to determine
training needs.
Step 10
Step 10
• Plan for and record anticipated
training completion dates.
• Write dates next to individual circles.
Step 11

20. General Information
Copyright 2001 - 2008 Lean Associates,
Inc.

21. General Information
Line Style SKETCH Proses critical Jenis mesin OUTPUT QUALITAS Nama operator NIK
Cross box Jarum 1 V V Saenur GIU 0494
Obras pasang tangan Obras benang 4 V Witri GIU 2351
Obras variasi samping Obras benang 4 V -
Tutup kerah Jarum 1 V V Khomsiyatun GIU 2088
Stick armhole Kamput V V Drsini GIU 0971
Cross box Jarum 1 V V Mila GIU 3636
Hemming tangan Kamput V -
Tutup kerah Jarum 1 V V Heni GIU 0273
Cross box Jarum 1 V V Masriah GIU 0277
Pasang kerah Jarum 1 V V Siti GIU 1956
Stick slit Jarum 1 V V Biut GIU 3783
Hemming tangan Kamput V V Suhartiningsih GIU 0758
Stick armhole /printing Kamput V Rohani GIU 0290
Make up Make up V V Risna GIU 0354
Obras kerah Obras benang 4 V V Nuraini GIU 0337
Stick zipper Jarum 1 V V iis GIU 0210
Tutup kerah Jarum 1 V V Elis GIU 4130
Pasang zipper Jarum 1 V V Mimin GIU 0217
Pasang zipper Jarum 1 V V Uli GIU 3204
Stick zipper Jarum 1 V V -
Corong tape kerah Jarum 1 V V -
Stick tape Jarum 1 V V -
Stick zipper Jarum 1 V V Kiswati GIU 2461
8 385 FA
395 FA
2
395 FA
12
7
5
P31142
MSTR08390
DATA CRITICAL PROSES SEWING
POLO
6
15
16
2. Select Best Operator To Do TOT (Training Of Trainer)

22. General Information
3. Train the best operator with
Lean Method (JI)
www.themegallery.com Company Logo

23. General Information

24. General Information

25. Perbaikan Terus-Menerus
❖ Update Weekly/Monthly untuk Skill Level %
❖ Merencanakan lebih awal jika ada resign dan rotasi
❖ Memperbaiki ISQ/RFT
Factory
Category Level - HR Data
S A B C
5% 25% 40% 30%
IY 01 12.4% 29.7% 34.5% 18.4%
IY 02 6.6% 17.0% 36.1% 26.1%
IY 03 7.9% 26.1% 35.7% 26.3%
IY 04 9.1% 27.5% 38.2% 21.4%
IY 05 9.1% 29.8% 28.5% 24.0%
IY 07 7.5% 31.4% 29.7% 19.8%
IY 08 7.3% 21.4% 36.8% 22.0%
IY 09 4.8% 15.1% 37.4% 29.2%
IY 10 6.0% 21.8% 40.3% 23.1%
IY 12 4.3% 21.1% 35.5% 25.6%
IY 13 6.9% 20.9% 33.9% 20.0%
IY 14 11.1% 36.1% 21.7% 23.4%
OUTSOLE 0.0% 34.8% 35.9% 4.0%
TOTAL 6.5% 25.9% 34.4% 20.3%

27. Train for mechanic
development
Test Skill

28. Visual Control Mechanic
Development Skill
No NAME Machine
Problem
Focus
Analyze Std
Total
Time
Setting
+ repair
(Minute
)
Education Skill
Update:
19 Feb
Update:
26 Mar
Update:
16 Apr
Update:
11 Mei
Update:
3 Jun
Update:
15 Jun
Update:
07 Jul
Update:
10
August
Update:
19 Feb
Update:
26 Mar
Update:
16 Apr
Update:
11 Mei
Update:
3 Jun
Update:
15 Jun
Update:
07 Jul
Update:
10
August
1 Dendi
Overdeck
( 3
Neddle,
Cutt )
Jumping
Stitch
3,7 3,8 3,9 3,6 3,7 3,9
20
2 Tatang 3,7 3,7 3,8 3,8 3,4 3,6 3,6 3,7
3 Aji 2,0 2,6 3,6 3,0 2,9 3,3
4 Jenal 3,3 3,7 3,7 3,3 3,4 3,7
5 Andre 3,1 3,3 3,7 3,3 3,3 3,4
6 Hari 4,0 4,0 3,9 3,9
7 Willy 2,8 3,1 3,2 2,7 2,7 3,0
NOTE
SCORE REMARKS
0 Can not repairing machine
1 Can carry out basic repairing machine
2 Can carry out basic repairing machine + requires intermediate supervision
3 Can carry out basic repairing machine + requires advance supervision
4 Can carry out basic repairing machine , propose improvement ideas, be able to work with
other Dept. & can train other mechanics to make repairs

29. Score Mechanic skill before & after
project
2.8
2.0
3.1
3.3
3.7 3.7
4.0
3.2
3.6 3.7 3.7 3.8 3.9 4.0
WILLY AJI ANDRE JENAL TATANG DENDI HARI
SKILL MATRIX MECHANIC
BEFORE AFTER
3.

30. Result on machine breakdown

31. ADD A FOOTER 31

32. Neal Creative ©
FINISH
IMPROVEMENTS!
THANK YOU