10. Modul 10 Pencapaian & Penciptaan Nilai KIK

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10. Modul 10 Pencapaian & Penciptaan Nilai KIK

  1. 1. MODUL 10: PENCAPAIAN DANPENCIPTAAN NILAI PAGE1
  2. 2. PENCAPAIAN DAN PENCIPTAAN NILAI• MENYATAKAN DAN MENYENARAIKAN FAEDAH, KEBAIKAN,MANFAAT, NILAI DLL YANG DIPEROLEHI DARIPADA HASIL PROJEK• MENGUKUR NILAI PENCAPAIAN• MEMBANDINGKAN ANTARA FAEDAH YANG DIPEROLEHI DENGAN KOS PERLAKSANAAN• MENGAITKAN FAEDAH PROJEK DAN SUMBANGANNYA KE ATAS PENCAPAIAN MISI DAN MATLAMAT SYARIKAT• MENYESUAIKAN SASARAN DENGAN PENCAPAIAN SEBENAR• PENCAPAIAN DAN PENCIPTAAN NILAI TELAH MENCAPAT PENGIKTIRAFAN DARI DALAM ATAU LUAR ORGANISASI PAGE2
  3. 3. PENCAPAIAN DAN PENCIPTAAN NILAI (SAMB…)• KESAN-KESAN KE ATAS PERSEKITARAN, KOMUNITI DAN SOSIAL BUKTI PENGESAHAN SEPERTI: SURAT PENGHARGAAN, SURAT PENGIKTIRAFAN, ANUGERAH YANG DITERIMA, TANDA ARAS, SESI PERKONGSIAN PENGETAHUAN• PENCAPAIAN DAN PENCIPTAAN NILAI DIKALANGAN AHLI• EG: CARTA RADAR, SOAL SELIDIK, SENARAI SEMAK• VERIFIKASI DAN PENGESAHAN TERHADAP PENCAPAIAN DAN PENCIPTAAN NILAI BUKTI PENGESAHAN: BAHAGIAN KEWANGAN, JURU AUDIT, SIRIM DLL PAGE3
  4. 4. CONTOHPAGE4
  5. 5. 6.1 .ACHIEVEMENT AND VALUE CREATION TANGIBLE BENEFIT REDUCE PROCESS STANDARD TIME MAN FROM 8 TO 7 PROCESS TIME MC STD. MAKING NCM CHUCK QC 5 FITTING 2 POWER SAW 1 19PROCESS CNC 3 60 MILLING 1 10 LATHE 90 NCL 18 120 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 PAGE5 TIME / MINUTES
  6. 6. 6.1 ACHIEVEMENT & VALUE CREATION TANGIBLE BENEFIT IMPROVED CYCLE TIME FROM 366 MIN TO 328 MIN TIME MAN ( 38 MINUTES ) TIME MC QC 5 STD. MAKING NCM CHUCK FITTING 2 ( NEW ) POWER SAW 1 19PROCESS CNC 3 60 MILLING 1 10 LATHE 90 NCL 18 120 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 PAGE6 TIME / MINUTES
  7. 7. 6.1 ACHIEVEMENT & VALUE CREATION TANGIBLE BENEFIT STOP NCM SETTING TIME LOST AT CUTTING SHOP SETTING TIME LOST REJECT 1.5 HRS x 10 PCS =15 HOURS 10PCS/MONTH 200 180 160 129 125 126 122 117 140 112 Output 120 86 100 80 Reject 60 40 10 8 15 9 8 10 10 20 0 Sept 04 Oct 04 Nov 04 Dec 04 Jan 05 Feb 05 AVE ZERO DEFECT SETTING Output 129 86 125 112 126 122 117 AT Reject 10 8 15 9 8 10 10 NCM MACHINE % MONTH SAVING 15 HRS/MONTH ZERO SETTING PAGE7 DEFECT1.5 HR = IS A STD. STTING TIME FOR NCM MACHINE BASE ON PIS.
  8. 8. 6.2 ACHIEVEMENT & VALUE CREATION QUANTUM OF ACHIEVEMENT OTHERS CHUCK PROCESS TIME SAVING MATERIAL REJECT COST SAVING PROCESS HR AVE. QTY TOTAL TYPE OF CHUCK IMPROVE /MONTH TIME (MIN) (PROCESS HR + RAW MTR ) X REJ.QTY X 12 ( 6.1 X 11.7 X 3.8 = RM 271.2 + 22.5 ) X 10 X 12 BOW CUTTING CHUCK 31 min 82 pcs 2548.20 ( 271.2 + 22.5 = RM 293.7 ) X 10 X 12 MIRROR CHUCK 20 min 222 pcs 4440.00 = RM 35,244.00/yr BUFFING CHUCK 20 min 210 pcs 4206.00 NCM SETTING SAVING NCL CHUCK 31 min 95 pcs 2954.30 STD.SETTING TIME ( PIS ) X MANAGERS RATE OTHERS 31 Min 322 10021.7 X EXCHANGE RATE X REJECT QTY X 12. 24170.2 / 60 = 402.8 hour TOTAL 24170.20 1.5HR X 11.7 X 3.8 X 10 X 12 402.8 X 11.7 X 3.8 = RM 17910.12 X 12 = RM 214,921.4 = RM 8,002.80/yr PROCESS IMPROVEMENT ( SAVING TIME ) COST OF PROJECT PROCESS HOUR SAVING ( IMPROVE ) X MGR.RATE X EXCHANGE RATE X 12 1) SMART JIG ( 6 ITEMS ) RM 1195.60 31 MINIT X 116.7 = 3618 MINIT / 60 = 60.3 HOUR 2) NCM SINGLE SETTING JIG RM 160.00 60.3 HOUR X 11.7 X 3.8 = RM 2680.9 X 12 3) QC NCM CHECKING JIG RM 58.50 = RM 32,171.30 /yr 4) AMADA COOLANT RM 598.40 5) POWER SAW BLADE RM 133.00 SLITTING SAW USAGE SAVING TOTAL SAVING PER YEAR AVEARAGE USAGE (MONTH) X UNIT PRICE A + B + C + D + COST INCURRED - - 15 X 151.65 = RM 2274.75 X 12 = RM 27,297.00/yr ERM317,610.00 RM 2,145.5 PAGE8NOTE : USD 11.7 IS A EPSON RATE ( MANAGERS RATE ) TO RM
  9. 9. 6.3 ACHIEVEMENT & VALUE CREATION RECONCILIATION OF THE TARGETREJECT 140 24 OUTPUT QTY 129 125 126 125 QTY (PCS) 22 122 121 120 (PCS) 20 112 106 18 100 97 16 86 15 14 80 MONITORING 12 11 DATA UNTIL 60 10 10 10 13/6/2005 9 8 8 8 40 6 6 4 20 2 0 0 0 0 Sept Oct Nov Dec Jan Feb M ac Apr M ay Jun July 04 04 04 04 05 05 05 05 05 05 05 Reject 10 8 15 9 8 10 11 6 0 0 Out put 129 86 125 112 126 122 106 121 125 97 Reject Out put PAGE9
  10. 10. 6. IMPLEMENTATION OF THE INNOVATIVE SOLUTION DATA COLLECTED DURING MONITORING16~20 MAY 16 ~ 20 MAYTime Study At Power Quality Monitoring At Power Saw Saw Machine. Machine16 ~ 18 MAYQuality Data For Off Center check PAGE10 Quality Monitoring At CNC Machine
  11. 11. 6.5. ACHIVEMENT & VALUE CREATION ENVIRONMENTAL / SOCIAL IMPACT NEW COOLANT – AMADA CUTTING SYNTHETIC SDSHELL TONNE OILS 66% WATER BASEENVIRONMENT HAZARD : ORGANIC ANTIRUST T M EN Not Ready biodegradable IR ON Expected to have a high NV RE Potential to Bio cumulate.. FO FE SA IT CAN MOVE TO ATMOSPHERE PAGE11 AND SOIL ENVIRONMENT.
  12. 12. 6.6. ACHIVEMENT & VALUE CREATION SELF- EXAMINATION SELF ASSESSMENT RADAR CHART TEAM WORK Together analysis the problem 6 Data collection Understanding the group 5 4 INVOLVEMENT 3 KNOWLEDGE OF QCC Involvement in learning new 2 Thing. Understanding the QCC concept & tools Involvement in dealing with 1 Understand the technical and User/others dpt. 0 Engineering knowledge. Involvement in problem solving. NETWORKING CONFIDENCE POOR EXCELLENT Manage to enhance working Confidence with the idea/ Relationship with various group Suggestion given High interactions with external Confidence project Will success QCC team. COMMITMENT 0 1 2 3 4 5 6 Commitment to the project. Commitment to group increase BEFORE START PROJECT TEAM WORK KNOWLEDGE CONFIDENCE INVOLV COMMITMENT NETWORKING PLANNING OF QCC MENT IMPROVEMENT BEFORE AFTER BEFORE AFTER BEFORE AFTER BEFORE AFTER BEFORE AFTER BEFORE AFTER AFTER PROJECT RONI 3 5 2.5 5 4 6 2.5 6 3 6 3 5 1. VERY POOR KAMAL 4 5.5 4 5.5 4 5.5 4 6 4 6 4 6 2. POOR DIANA 3 5 2.5 5 4 6 2.5 6 3 6 3 5 3. GOOD 6 5 NORLIDAH 3 5 2.5 5 4 6 2.5 3 6 3 4. VERY GOOD PAGE12 AV ERA GE 3 5 2.5 5 4 6 5 6 6 3 6 3 5. EXCELLENCESOURCE : SURVEY FEEDBACK FROM 6. VERY EXCELLENCE
  13. 13. 6.7.ACHIEVEMENT & VALUE CREATION VERIFICATION AND VALIDATION DEPARTMENT MGR.CUTTING SHOP CONGRATULATIONS !!!! CONGRATULATIONS FOR YOUR ACHIVEMENT!!! CUTTING MANAGER THEME COMPLETION ( BUSINESS PLAN REPORT) PAGE13 78
  14. 14. 6. IMPLEMENTATION OF THE INNOVATIVE SOLUTION RESULT MONITORING AFTER IMPLEMENTATION HISTOGRAM – OFFCENTER CHECK HISTOGRAM OF INNER SETTING DIAMETER.NAME OF PRODUCT : NCM CHUCKCHECK ITEMS : INNER SITTING DIAMETER VS NAME OF PRODUCT : NCM CHUCK TOP PROFILE. CHECK ITEMS : INNER SITTING DIAMETERNO. OF SAMPLE : 100PCS. NO. OF : 100PCS. LCL UCL LCL UCL 46.000 - 0.000 + 0.020 RANGE OF RANGE OF THE RANGE OF THE PRODUCT THE PRODUCT PRODUCT 35 40 37 FREQUENCY 29 35F 30R 30E 25QU 20 HISTOGRAM 25 20 20 18E 20N 14 NORMAL DISTRIBUTION 15 15 13C 11 UNDER CONTROL.15Y 10 8 10 6 6 5 5 0 46.0000 46.0200 0 CLASSES BOUNDARY 46.0015 - 46.0044 46.0045 - 46.0074 46.0075 - 46.0104 46.0105 - 46.0134 46.0135 - 46.0164 46.0165 - 46.0194 46.0195 - ke ONWARDS atas CLASSES BOUNDRY 0.050 0.0000 0.0050- 0.0094 0.0095 - 0.0194 0.0195 - 0.0294 0.0295- 0.0394 0.0395 - 0.0494 PAGE14 0.0495 - ONWARDS
  15. 15. 10. REVIEW & CONTINUOUS IMPROVEMENT MONITORING RESULT AFTER IMPLEMENTATION 80REJECT 24 OUTPUT QTY 22 72 71 QTY 70 70 70 70 (PCS) 65 68 (PCS) 20 61 62 60 18 56 52 53 52 16 50 14 12 40 10 30 8 7 RESULT 6 6 20 5 5 5 UNTIL AUG.05 4 4 4 3 10 2 0 0 0 0 0 0 0 Sept Oct Nov Dec Jan Feb M ac Apr M ay Jun July A ug Sep Oct 04 04 04 04 05 05 05 05 05 05 05 05 05 05 Reject 5 4 4 7 5 5 6 3 0 0 0 0 0 Out put 52 61 53 72 52 56 70 71 70 65 70 68 62 Reject Out put PAGE15
  16. 16. PARETO GRAPH – BEFORE AND AFTER PROJECT BEFORE AFTER AVERAGE REJECT / MONTH REJECT DATA MAY 05 100 100 28 28 100% 92.0 26 90 26 ELEMINATE NCM CHUCK 24 24 79.8 80 OFFSET 22 22 20 70 20 65.9 % 18 60 18 100 88.1 100 16REJ.QTY 16 REJ.QTY 51.2 90 14 50 14 70.5 80 12 10 40 12 70 52.9 10 34.8 10 60 8 30 50 8 40 6 4.7 20 6 5 4.2 4 29.4 4 30 3.5 3 3 4 2.3 4 2 20 10 2 2 10 0 0 0 0 0 MATERIAL MATERIAL BROKEND PUNCH/DIE BROKEND PUNCH/DIE COVERING JIG NCM CHUCK CUTTER COVERING JIG CUTTER NCM CHUCK BUFFING/MIRROR CRACK BUFFING/MIRROR CRACK DELAY OFFSET DELAY OFFSET WEAR OFF WEAR OFF CHUCK REJ. CHUCK REJ. PROBLEM PROBLEM REJECT QTY ACC REJECT QTY ACC PAGE16

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