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TMMIN-CEVD 1
sum
atra
kalim
antan
Jawa
Sulawesi
Papua
TMMIN
CEVDARGENTINA
BRAZIL
VENEZUELA
SOUTH
AFRICA
SAUDI
ARABIA
(CBU)...
TMMIN-CEVD
SCHEDULE ACTIVITY : Plan
: Actual
N
O 8 STEP QCC OKT 2012 NOV 2012 DES 2012 JAN 2013
1 PEMILIHAN TEMA
2 ANALISA...
TMMIN-CEVD
IDEA SUGESTION
( Participant . 7 MP )
%
Target / month : 100
CONSUMABLE
( sarung tangan katun )
PCS
Target / mo...
TMMIN-CEVD
Tema :
“ MENURUNKAN WAKTU
PROSES STACKING PART
SPRING COIL MAIN JOB
CASE COA’’
60953 60346 6034661560
0
10000
2...
TMMIN-CEVD
Base
Stacking
1
Base
Stacking
2
Store label
Store
Spring coil
Safetyguard
Supplier
Receiving part
Progress line...
TMMIN-CEVD
CYCLE TIME
25 26
24 25 25
5
10
15
20
25
15 16 17 18 19
DATE ( OKT '12 )
DETIK
Data Pengamatan
Ave :
25”
Ideal :...
TMMIN-CEVD
MP harus memilah box part
Sebelum tempel label
MP langsung tempel label setelah
pencocokan no lot label vs E-ka...
TMMIN-CEVD
Mp mendorong dolly ringan
Isi 8 box untuk 2 case
Mp mendorong dolly berat
isi 8 box untuk 2 case
FAKTOR CONTROL...
TMMIN-CEVD
ideal :
104”
123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN
Mp sulit & cepat lelah saat
mem...
TMMIN-CEVD
255
265
275
285
295
305
315
325
335
345
355
365
DETIK
Bulan Jul ‘12 Agt ‘12 Sep ‘12 Okt ‘12 Nov ‘12 Des ‘12 Jan...
TMMIN-CEVD 11
PROSES ROOT CAUSED FACTOR
Tgl pengamatan
( C/T ) Ave RANK
12 13 14 16
Tutup pagar base
stacking
Mp melangkah...
TMMIN-CEVD 12
5.1. Plan Decission Program Chart ( PDPC ) ke 1
What How Where When Who Why How much
Problem Temporarymeasur...
TMMIN-CEVD 13
5.3. Plan Decission Program Chart ( PDPC ) ke 3
What How Where When Who Why How much
Problem Temporarymeasur...
TMMIN-CEVD
123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN
Mp sulit saat memasang hanger ke box part
( ...
TMMIN-CEVD
Mp harus membuka &
mengencangkan bolt stoper
123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN...
TMMIN-CEVD
Mengganti stoper baut menjadi
stoper geser yang fleksibel
Idea no. 4
15cm
48cm
10cm
15cm
STOPER
GESER
123-THIN-...
TMMIN-CEVD
Mp tidak perlu memilah box part
Isi dalam 1 messpallet lebih dari 1 lot
Lot 1
Lot 2
Merubah isi dalam satu mess...
TMMIN-CEVD
messpallet
Pengiriman part dari supplier
langsung 8 box / messpalet ( 160
kg )
8
7
6
5
1
4
2
3
Mp mendorong dol...
TMMIN-CEVD
Langkah Mp berkurang, Mp cukup membuka atau
memutar tuas pengunci untuk menutup pagar
Arah Gaya
Gravitasi
Pembe...
TMMIN-CEVD
235
255
275
295
315
335
355
375
DETIK 20
BULAN JUL ‘12 AGT ‘12 SEP ‘12 OKT ‘12 NOV ‘12 DES ‘12 JAN ‘13
MINGGU I...
TMMIN-CEVD
COST
DAMPAK POSITIF TERHADAP 5 MAJOR MISSION
Safety
Proses stacking lebih aman & nyaman
( ergonomic point up da...
TMMIN-CEVD 22
8.1.STANDARISASI
SOP. Mengoperasikan safety
guard power less ( karakuri system )
SOP. Mengoperasikan dolly m...
TMMIN-CEVD
11601200
0
200
400
600
800
1000
1200
1400
Direct Indirect
DETIK
C. Grafik C/T Stacking
  Case C6 ASSB By
Proces...
Circle
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Contoh QCC Presentation

  1. 1. TMMIN-CEVD 1 sum atra kalim antan Jawa Sulawesi Papua TMMIN CEVDARGENTINA BRAZIL VENEZUELA SOUTH AFRICA SAUDI ARABIA (CBU) PAKISTANINDIA CINA THAILAND VIETNAM MALAYSIA JAPAN TAIWAN PHILIPINES MESIR (EGYPT) Area kerja (QCC)
  2. 2. TMMIN-CEVD SCHEDULE ACTIVITY : Plan : Actual N O 8 STEP QCC OKT 2012 NOV 2012 DES 2012 JAN 2013 1 PEMILIHAN TEMA 2 ANALISA KONDISI YG ADA 3 PENETAPAN TARGET 4 ANALISA SEBAB AKIBAT 5 RENCANA PENANGGULANGAN 6 PENANGGULANGAN 7 EVALUASI HASL 8 STANDARDISASI & TINDAK LANJUT 0 25 50 75 100 SKILL & MOTIVATION 8 step ( 68% ) 7 tool ( 66% ) Spirit ( 81% ) Tanoko ( 65% ) Average : 69 % 2 Nama Group Dibentuk Kehadiran Tema Selesai : COMPAQ : 08–03-2004 : 98% : 15 tema STRUKTUR ORGANISASI LEVEL ASSESSMENT Assessor Assessment Level 1 2 3 4 5 GoodY High X 5 1 3 4 2 C-1 zone WORKPLACECONDITION D-1 zone B zone D zone C-2 zone C zone AAN DARMAWAN 1 2 3 4 5 Y 5 1 3 4 2 5 1 3 4 2 Current Level ZONE C Current X = 3 Y = 3 D-2 zone 06 SEP 2012 A zone QCC SKILL 11stst winnerwinner at CEVD Conventionat CEVD Convention Periode Okt ’12 - Mar ‘13Periode Okt ’12 - Mar ‘13
  3. 3. TMMIN-CEVD IDEA SUGESTION ( Participant . 7 MP ) % Target / month : 100 CONSUMABLE ( sarung tangan katun ) PCS Target / month : 110 1.68 1.68 1.69 243205 223443 235654 0.1 0.3 0.5 0.7 0.9 1.1 1.3 1.5 1.7 1.9 Jul 2012 Agt 2012 Sep 2012 210000 220000 230000 240000 250000 260000 270000 280000 290000 300000 Man hour Loading time DATA MAN HOUR DETIK M/H Target / month : 1.70 NEXT PROCESS CLAIM PPM Target / month : 1 WORK ACCIDENT ACCIDENT Target / month : 0 Target Hoshin, fy 12-13 : 100Target Hoshin, fy 12-13 : 110 3 DATA 5 MAJOR MISSION LINE ASSY SET BULAN JULI – SEPTEMBER 2012 Target Hoshin, fy 12-13 : 0 Target Hoshin, fy 12-13 : 0 Target Hoshin, fy 12-13 : 1.53 KPI 5 Major Mission Line Assy Set Jul – Sep 2012
  4. 4. TMMIN-CEVD Tema : “ MENURUNKAN WAKTU PROSES STACKING PART SPRING COIL MAIN JOB CASE COA’’ 60953 60346 6034661560 0 10000 20000 30000 40000 50000 60000 70000 STACKING 1 STACKING 2 PICKING 1 PICKING 2 DETIK 1a. Yamazumi loading time line assy set / day September 2012 4 Target : 55045” 1b. Stratifikasi Loading time stacking 1 by destination September 2012 Destination Case type Qty case ( monthly ) Stacking time Loading time Rank ASSB ( Malaysia ) C6 52 2360 5578 IV C8 52 1526 3607 VII TMP ( Philipine ) C6 132 1632 9792 III C7 132 1650 9900 II C8 16 845 615 VIII C0A 264 831 9972 I TMV ( Vietnam ) C0 22 1560 1560 XII C6 44 2458 4916 VI C21 44 1130 2260 IX C17 44 990 1980 X C7 44 4010 8020 V C8 44 1680 3360 XI Total 61560 1c. Pareto process stacking 1 Case COA TMP by klasifikasi job 37 81 713 0 100 200 300 400 500 600 700 800 MAIN PREPARE INCIDENTIL DETIK -0 -50% -100% 89% 96%N = 831 -0 -50% -100% 1d. Pareto process main job stacking 1 case COA by process 182 71 68 36 356 0 100 200 300 400 500 600 700 Stacking part spring coil Tutup module dengan plastik 5M Check no. box label vs Content list Pasang case mark Scan barcode case mark DETIK N = 713 50% 75% 85% 95%
  5. 5. TMMIN-CEVD Base Stacking 1 Base Stacking 2 Store label Store Spring coil Safetyguard Supplier Receiving part Progress line 1 2 3 4 6 5 Finish Good Vanning Importer Picking 1 Picking 2 Stacking 2 Stacking 1 Direct stacking 123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN 123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN123-THIN- PER PT. TMMIN K- LINE 5 A. Pengamatan process stacking spring coil case COA
  6. 6. TMMIN-CEVD CYCLE TIME 25 26 24 25 25 5 10 15 20 25 15 16 17 18 19 DATE ( OKT '12 ) DETIK Data Pengamatan Ave : 25” Ideal : 10” Waktu Ideal Yokoten dari Safety Guard Receiving,C/T :10’’ Mp tidak ada langkah saat tutup pagar Mp banyak langkah saat tutup pagar ( ± 12 langkah ) B.1. Hasil analisa 4M+1E FAKTOR CONTROL ITEM CONTROL POINT KONDISI AKTUAL KONDISI IDEAL Potensi Material Pagar Bahan pagar Terbuat dari besi Terbuat dari besi Tidak ada Machine Roda pagar Fungsi roda pagar Berputar Berputar Tidak ada Methode Pagar base stacking Tutup pagar base stacking Mp banyak langkah saat tutup pagar ( ± 12 langkah ) Mp tidak ada langkah saat tutup pagar Ada Man MP Skill Level 3 Level 3 Tidak ada Environment Lantai Kondisi lantai Tidak berlubang Tidak berlubang Tidak ada 6 Ambil label Dorong dolly spring ke module Masukan box part ke dalam module Kembalikan dolly ke storenya 1 4 Tutup pagar Base stacking 2 5 6 Picking part spring coil 3 Tutup pagar Base stacking 2 Ave : 25” Ideal : 10”
  7. 7. TMMIN-CEVD MP harus memilah box part Sebelum tempel label MP langsung tempel label setelah pencocokan no lot label vs E-kanban FAKTOR CONTROL ITEM CONTROL POINT KONDISI AKTUAL KONDISI IDEAL Potensi Material Label Bahan label Terbuat dari kertas Terbuat dari kertas Tidak ada Machines Dolly picking Fungsi Layak pakai Layak pakai Tidak ada Methode Picking part Tempel label Mp harus memilah box part sebelum tempel label MP langsung tempel label setelah pencocokan no lot label vs E-kanban Ada Man MP Skill Level 3 Level 3 Tidak ada Environment Lantai Kondisi lantai Rata & tidak licin Rata & tidak licin Tidak ada 7 B.2. Hasil analisa 4M+1E Ambil label Dorong dolly spring ke module Masukan box part ke dalam module Kembalikan dolly ke storenya 1 4 Tutup pagar Base stacking 2 5 6 Picking part spring coil 3 Picking part spring coil 3 CYCLE TIME 108 107 108 109 108 60 70 80 90 100 110 15 16 17 18 19 DATE( OKT '12 ) DETIK Data Pengamatan Ave : 108” ideal : 72” Waktu Ideal Yokoten dari Proses Picking Duct Cooler,C/T :72’’ Ave : 108” ideal : 72”
  8. 8. TMMIN-CEVD Mp mendorong dolly ringan Isi 8 box untuk 2 case Mp mendorong dolly berat isi 8 box untuk 2 case FAKTOR CONTROL ITEM CONTROL POINT KONDISI AKTUAL KONDISI IDEAL Potensi Material Dolly Bahan dolly Terbuat dari besi Terbuat dari besi Tidak ada Machines Dolly fungsi Tidak rusak Tidak rusak Tidak ada Methode Dorong dolly Dorong dolly ke area stacking Mp mendorong dolly berat isi 8 box untuk 2 case Mp mendorong dolly ringan isi 8 box untuk 2 case Ada Man MP Skill Level 3 Level 3 Tidak ada Environment Area stacking Area dolly Tidak sempit Tidak sempit Tidak ada 8 B.3. Hasil analisa 4M+1E Ambil label Dorong dolly spring ke module Masukan box part ke dalam module Kembalikan dolly ke storenya 1 4 Tutup pagar Base stacking 2 5 6 Picking part spring coil 3 Dorong dolly spring ke module 4 CYCLE TIME 46 44 46 48 46 25 30 35 40 45 15 16 17 18 19 DATE ( OKT '12 ) DETIK Data Pengamatan Ave : 46” Ideal : 30” Waktu Ideal Yokoten dari dorong Dolly Part Rod Assy,C/T :30’’ Ave : 46” Ideal : 30”
  9. 9. TMMIN-CEVD ideal : 104” 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN Mp sulit & cepat lelah saat memasukan box part ke module Ave : 132” 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN Mp mudah saat memasukan box part ke module FAKTOR CONTROL ITEM CONTROL POINT KONDISI AKTUAL KONDISI IDEAL Potensi Material Carton box Bahan carton Terbuat dari kertas Terbuat dari kertas Tidak ada Machines Roda dolly Berfungsi Berputar balik Berpuitar balik Tidak ada Methode Box part Memasukan box part Mp sulit & cepat lelah saat memasukan box part ke module Mp mudah saat memasukan box part ke module Ada Man Mp Skill Mp Level 3 Level 3 Tidak ada Environment Lantai Kondisi lantai Tidak berlubang Tidak berlubang Tidak ada 9 B.4. Hasil analisa 4M+1E Ambil label Dorong dolly spring ke module Masukan box part ke dalam module Kembalikan dolly ke storenya 1 4 Tutup pagar Base stacking 2 5 6 Picking part spring coil 3 Masukan box part ke dalam module 5 CYCLE TIME 132 132 131 133 132 90 100 110 120 130 15 16 17 18 19 DATE( OKT '12 ) DETIK Data Pengamatan Ave : 132” ideal : 104” Waktu Ideal Yokoten dari Proses Stacking Duct Cooler,C/T :104’’ Summary genba, genchi, genbutsu di area stacking 1 Kondisi AKTUAL sesuai STANDART, group kami sepakat meningkatkan eficiency kerja yokoten dari tempat lain yang lebih mudah & cepat ( IDEAL ) Kesimpulan : No Flow proses stacking spring coil ACT STD IDEAL Benchmark from process Potensi Improvement 1 Ambil label 10 10 10 Ambil label part Duct Cooler Tidak ada 2 Tutup pagar base stacking 25 25 10 Tutup safety guard di area receiving part ( logistic ) Ada 3 Picking part spring coil 108 108 72 Picking part Duct Cooler Ada 4 Dorong dolly spring ke module 46 46 30 Dorong dolly part Rod Assy Ada 5 Masukan box part ke dalam module 132 132 104 Stacking part Duct Cooler Ada 6 Kembalikan dolly ke storenya 35 35 35 Stacking part Duct Cooler Tidak ada TOTAL 356 356 261
  10. 10. TMMIN-CEVD 255 265 275 285 295 305 315 325 335 345 355 365 DETIK Bulan Jul ‘12 Agt ‘12 Sep ‘12 Okt ‘12 Nov ‘12 Des ‘12 Jan ‘13 Minggu I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV Cycle time 356 358 354 356 356 357 356 355 355 357 356 356 357 355 356 356 261 SSpecifik MMeasurable AAchieveble RReasonable TTimephase Menurunkan waktu stacking part SPRING COIL main job Case COA TMP dari average 356” menjadi 261” Satuan yang digunakan adalah DETIK Ideal waktu process stacking spring coil = 261” Penurunan waktu = 356”- 261” = 95” Persentase penurunan = 95/356x100% = 26,7%  Support aktifitas & mengacu pada action plan / hoshin  Berdasarkan study kasus pada stacking part spring coil Batas waktu penanggulangan sampai dengan minggu ke 1 bulan januari 2013 BEFORE QCCBEFORE QCC INVESTIGATIONINVESTIGATION AFTER QCCAFTER QCC 10 Grafik Target Penurunan Waktu Stacking PGrafik Target Penurunan Waktu Stacking Partart SPRING COILSPRING COIL Main JobMain Job CaseCase COA TMPCOA TMP Bulan JuliBulan Juli 20122012 –– JanuariJanuari 20120133 261 Target 261Average : 356
  11. 11. TMMIN-CEVD 11 PROSES ROOT CAUSED FACTOR Tgl pengamatan ( C/T ) Ave RANK 12 13 14 16 Tutup pagar base stacking Mp melangkah dari Store label ke store pagar dan mendorong pagar sejauh ±5M Methode 26 25 25 24 25 IV Picking spring coil Isi dalam 1 messpallet lebih dari 1 lot 102 101 102 103 102 II Dorong dolly ke area module Pengiriman part dari supplier langsung 8 box / dolly messpalet 42 41 42 43 42 III Masukan box part kedalam module Proses memasukan box part diangkat manual 4x bolak balik ( 20kg/box ) 126 126 127 125 126 I Total 295 Data problem proses stacking coil , November 2012 Mp mendorong dolly berat, isi dalam dolly 8 box ( 160kg ) Mp harus memilah box part sesuai lot yang dibutuhkan Box part tercampur dengan lot yang berbeda Mp sulit & cepat lelah saat memasukan box part ke module Mp banyak langkah saat tutup pagar ( ± 12 x ) METHODE Proses memasukan box part diangkat manual 4x bolak balik ( 20kg/box ) Pengiriman part dari supplier langsung 8 box per messpallet Isi dalam 1 messpallet lebih dari 1 lot Mp melangkah dari Store label ke store pagar dan mendorong pagar sejauh ±5M Waktu Proses Stacking part spring coil tinggi METHODE I II III IV Pareto problem proses stacking spring coil , November 2012 25 42 102 126 0 50 100 150 200 250 Rank I Rank II Rank III Rank IV DETIK -0 -50% -100% 43% 77% N = 295 92% 1 2 3 4 5 6 7 8 Lot 1 Lot 2 Store label
  12. 12. TMMIN-CEVD 12 5.1. Plan Decission Program Chart ( PDPC ) ke 1 What How Where When Who Why How much Problem Temporarymeasure Countermeasure Aktifitas Lokasi Waktu PIC Alasan target Biaya Mp sulit &cepat lelah saat memasukan box part ke module Penempatan box part di dolly hydrolic Dibuatkan alat bantu pengangkat box part Meeting group Konfirmasi atasan Design tool Fabrikasi Trial dan evaluasi OASIS OASIS OASIS W/shop LINE 03-12-12 03-12-12 03-12-12 05-12-12 Doni A. Agung Agung Domi Agar Mp tidak cepat lelah Kontribusi target reduce : C/T aktual – C/T ideal 132” – 104” = 28” dibulan Des ’12 minggu ke 3 Total investasi Rp 4.668.000 What How Where When Who Why How much Problem Temporarymeasure Countermeasure Aktifitas Lokasi Waktu PIC Alasan target Biaya Mp harus memilah box part sesuai lot yg dibutuhkan Grouping box part per lot diarea receiving Isi dalam 1 messpallet dibuat per lot Meeting group Konfirmasi atasan Meeting dengan PSE dan supplier Trial & evaluasi OASIS OASIS OASIS Line 03-12-12 03-12-12 05-12-12 15-12-12 Doni A. Agung Agung Domi Agar mp tidak memilah box Kontribusi target reduce : C/T aktual – C/T ideal 108” – 72” = 36” dibulan Des ’12 minggu ke 3 Total investasi Rp 1.360.000 5.2. Plan Decission Program Chart ( PDPC ) ke 2 Alternatif 1 Quantity dalam 1 box ditambah menjadi 10 pcs Alternatif 2 Quantity dalam 1 box dibuat 2 pcs/box Alternatif 3 Qty dalam 1 box tetap ( 20kg ) dan dibuatkan alat bantu pengangkat box part Box part berat saat diangkat ( ± 40 kg ) Proses memasukan box part 10x bolak balik Proses Memasukan Box Part Mudah Dan Mp tdk Cepat lelah Proses memasukan box part diangkat manual 4x bolak balik ( 20kg/box ) 3 point 3 point 7 point X X Isi dalam 1 messpallet lebih dari 1 lot Alternatif 1 Box part di pilah menjadi per Lot di area receiving Alternatif 2 Box part di masukan kedalam F/R Alternatif 3 Isi dalam 1 messpallet dibuat per Lot Penambahan Proses di Area Receiving Proses supplay part berat dan lama Proses Picking Box Part Mudah Dan Cepat 4 point 4 point 6 point X XLot 1 Lot 2
  13. 13. TMMIN-CEVD 13 5.3. Plan Decission Program Chart ( PDPC ) ke 3 What How Where When Who Why How much Problem Temporarymeasure Countermeasure Aktifitas Lokasi Waktu PIC Alasan target Biaya Mp mendorong dolly berat, isi dalam dolly 8 box ( 160 kg ) Beban muatan dikurangi dari 8 box menjadi 4 box Dipasang Motor Electritc pada Dolly Meeting group Konfirmasi atasan Meeting dg Workshop Design dolly Trial & evaluasi OASIS OASIS OASIS OASIS Line 03-12-12 03-12-12 05-12-12 15-12-12 Doni A. Agung Adhana Tiara Winarto Mp mendorong dolly ringan Kontribusi target reduce : C/T aktual – C/T ideal 46” – 30” = 16” dibulan Des ’12 minggu ke 4 Total investasi Rp 8.025.000 What How Where When Who Why How much Problem Temporarymeasure Countermeasure Aktifitas Lokasi Waktu PIC Alasan target Biaya Mp banyak langkah saat tutup pagar ( ± 12x ) N/A Dibuatkan safety guard power less ( karakuri system) Meeting group Konfirmasi atasan Meeting dg Workshop Design pagar Trial & evaluasi OASIS OASIS OASIS OASIS Line 03-12-12 03-12-12 05-12-12 05-12-12 05-12-12 Doni A. Agung Adhana Tiara Winarto Mp tidak banyak langkah Kontribusi target reduce : C/T aktual – C/T ideal 26 – 10 = 16” dibulan Des ’12 minggu ke 4 Total investasi Rp 3.845.000 5.4. Plan Decission Program Chart ( PDPC ) ke 4 Alternatif 1 Beban Muatan dikurangi dari 8 box menjadi 4 box Alternatif 2 Dibuatkan dolly special sesuai spec kapasitas Membutuhkan dua dolly, muda langkah ambil dolly Ukuran dolly lebih besar tidak bisa masuk ke area stacking Dorong doly ringan, mudah dan cepat Pengiriman part dari supplier langsung 8 box per messpallet Alternatif 3 Dipasang Motor Electric pada Dolly 4 point 4 point 5 point X X 1 2 3 4 5 6 7 8 Mp melangkah dari store label ke store pagar dan mendorong pagar sejauh ±5M Alternatif 1 Dipasang rel & kabel sling pada roda pagar Alternatif 2 Dibuatkan safety guard elektrik Alternatif 3 Dibuatkan safety guard power less ( karakuri system ) Langkah berkurang, tetapi proses tutup pagar dengan cara di tarik ( muda proses ) Cost pembuatan besar Proses penutupan pagar Base stacking lebih cepat 4 point 5 point 7 point X XStore label
  14. 14. TMMIN-CEVD 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN Mp sulit saat memasang hanger ke box part ( setting ujung hanger di lubang box part berkali-kali ) 31 cm 51 cm 4 cm 3 cm Hanger Dibuatkan alat bantu pengangkat box part rr 300cm Hoist Weigth Capacity 200kg 300cm 30cm 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN module Proses memasukan box part diangkat manual 4x bolak balik ( 20kg/box ) 14 6.1. PENANGGULANGAN KE 1 Waktu proses memasukkan box part spring coil ke module belum tercapai 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN module Mp sulit & cepat lelah saat memasukan box part ke module Idea no. 2 Idea no. 1 Bulan OKT 2012 Nov 2012 Des 2012 Minggu I II III IV I II III IV I II III C/T 133 132 132 131 126 126 125 127 126 126 136 80 90 100 110 120 130 140 150 DETIK Target : 104 Ave : 132 Target reduce : 28” KaizenBefore Investigasi + temp.measure Aktual : 136 Aktual increase : 4” Temp.meausure
  15. 15. TMMIN-CEVD Mp harus membuka & mengencangkan bolt stoper 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN 15 Mengganti hanger model jepit Menjadi model lurus 6.1. PENANGGULANGAN KE 1 ( PDCA #1 ) Mp sulit saat memasang hanger ke box part Waktu proses memasukkan box part spring coil ke module belum tercapai Mp harus meregangkan hanger METHODE Mp sulit saat memasang hanger ke box part Bentuk hanger model jepit 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN rr Idea no. 3 STOPER BAUT Bentuk hanger model jepit Bulan Okt’12 (ave) Okt’12 (ave) Des 2012 Minggu I II III IV C/T 132 126 132 132 136 112 50 60 70 80 90 100 110 120 130 140 150 160 DETIK Target : 104 Aktual reduce : 20” Target reduce : 28” KaizenBefore Aktual : 136 Aktual ( PDCA#1 ) : 112 Investigasi + temp. measure Ave : 132 Temp.measure 15cm 48cm 10cm 15cm
  16. 16. TMMIN-CEVD Mengganti stoper baut menjadi stoper geser yang fleksibel Idea no. 4 15cm 48cm 10cm 15cm STOPER GESER 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN Mp harus membuka dan mengencangkan stoper baut 16 Stopper hanger tidak fleksibel 6.1. PENANGGULANGAN KE 1 ( PDCA #2 ) Waktu proses memasukkan box part spring coil ke module sesuai target Mp harus membuka dan mengencangkan Stoper baut METHODE Waktu proses memasukan box part belum tercapai Stopper hanger tidak fleksibel STOPER BAUT Bulan Okt’12 (ave) Okt’12 (ave) Des 2012 Jan 2013 Minggu I II III IV I II C/T 132 126 132 132 136 112 92 92 50 60 70 80 90 100 110 120 130 140 150 160 DETIK Target : 104 Aktual reduce : 40” Target reduce : 28” KaizenBefore Aktual : 136 Aktual ( PDCA#1 ) : 112 Investigasi + temp. measure Ave : 132 Temp.measure Aktual ( PDCA#2 ) : 92 Proses pemasangan hanger di box part lebih mudah & cepat 123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN123-THIN-PER PT. TMMIN Cukup digeser sekali
  17. 17. TMMIN-CEVD Mp tidak perlu memilah box part Isi dalam 1 messpallet lebih dari 1 lot Lot 1 Lot 2 Merubah isi dalam satu messpallet menjadi 1 lot Idea no. 5 Lot 1 Mp harus memilah box part sesuai lot yang dibutuhkan 17 Waktu proses picking part spring coil sesuai target 6.2. PENANGGULANGAN KE 2 Bulan OKT 2012 Nov 2012 Des 2012 Minggu I II III IV I II III IV I II III C/T 108 108 108 109 107 108 109 108 108 108 68 50 60 70 80 90 100 110 120 DETIK Target : 72 Ave : 108 Target reduce : 36” KaizenBefore Investigasi + temp.measure Aktual : 68 Aktual Reduce : 40” Temp.meausure
  18. 18. TMMIN-CEVD messpallet Pengiriman part dari supplier langsung 8 box / messpalet ( 160 kg ) 8 7 6 5 1 4 2 3 Mp mendorong dolly ringan Mp mendorong dolly berat Isi 8 box untuk 2 case Waktu proses mendorong dolly ke area stacking sesuai target 6.3. PENANGGULANGAN KE 3 18 Dibuatkan motor electric pada dolly ( Dolly Motor ) Idea no. 6 10 15 20 25 30 35 40 45 50 55 DETIK Target : 30 Ave : 46 Target reduce : 16” KaizenBefore Investigasi + temp.measure Aktual : 26 Aktual Reduce : 20” Temp.meausure Bulan Okt 2012 Nov 2012 Des 2012 Minggu I II III IV I II III IV I II III IV C/T 46 46 46 46 43 42 42 41 42 43 42 26 Motor electric Handle Gas Handle Rem Baterai Lamp indikator
  19. 19. TMMIN-CEVD Langkah Mp berkurang, Mp cukup membuka atau memutar tuas pengunci untuk menutup pagar Arah Gaya Gravitasi Pemberat / bandul 105cm 25cm 105cm Seling (kawat) Store label Tuas pengunci Pedal Box control Dibuatkan safety guard power less ( karakuri system ) Idea no.7 Mp banyak langkah saat tutup pagar ( ± 12 langkah ) Waktu proses menutup pagar sesuai target 6.4. PENANGGULANGAN KE 4 19 Mp melangkah dari Store label ke store pagar dan mendorong pagar sejauh ±5M 0 5 10 15 20 25 30 35 DETIK Target : 10 Ave : 25 Target reduce : 15” KaizenBefore Investigasi Aktual : 8 Aktual Reduce : 17” Bulan Okt 2012 Nov 2012 Des 2012 Minggu I II III IV I II III IV I II III IV C/T 26 25 25 25 25 25 24 26 25 26 25 8
  20. 20. TMMIN-CEVD 235 255 275 295 315 335 355 375 DETIK 20 BULAN JUL ‘12 AGT ‘12 SEP ‘12 OKT ‘12 NOV ‘12 DES ‘12 JAN ‘13 MINGGU I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV C/T 356 358 354 356 356 357 356 355 355 357 356 356 357 355 356 356 340 340 339 341 340 342 316 259 239 238 238 239 Grafik penurunan waktu process stacking part spring coil main job case C0A TMP di line assy set , Juli 2012 – Januari 2013 Average 356 Target 261 Actual 239 BEFORE QCCBEFORE QCC INVESTIGATIONINVESTIGATION KAIZENKAIZEN AFTER QCCAFTER QCC Kaizen 1 PDCA #2 Kaizen 1 PDCA #1 Kaizen 3 & 4 Kaizen 1 & 2 AFTER QCCBEFORE QCC Pareto process main job stacking 1 case COA by process 182 71 68 36 356 0 100 200 300 400 500 600 700 Stacking part spring coil Tutup module dengan plastik 5M Check no. box label vs Content list Pasang case mark Scan barcode case mark DETIK N = 713 50% 75% 85% 95% 71 68 36 182 239 0 100 200 300 400 500 Stacking part spring coil Tutup module dengan plastik 5M Check no. box label v s Content list Pasang case mark Scan barcode case mark DETIK -0 -50% -100%N = 596 40% 71% 83% 93% -0 -50% -100% Reduce 33% Reduce 16.4% MAN HOUR 1.69 1.65 232057 243205 1.59 1.61 1.63 1.65 1.67 1.69 BEFORE(Sep 2012)AFTER (Jan 2013) 220000 225000 230000 235000 240000 245000 250000 255000 260000 Man hour Loading time DETIK M/H Temporary measure
  21. 21. TMMIN-CEVD COST DAMPAK POSITIF TERHADAP 5 MAJOR MISSION Safety Proses stacking lebih aman & nyaman ( ergonomic point up dari -43→-12, WRAS Rank down dari Ab→Bc ) Quality Possibility part cacat akibat handling dapat dihilangkan ( zerro defect ) Productivity Reduce stacking time spring coil :117” Dari sebelumnya 356” → 261” Cost Reduce cost stacking time Rp 1120 / case Dari sebelumnya Rp 5040 → Rp 3920 HR Development Pembuatan ide berkonsep 2 lembar / mp dapat dipertahankan sesuai target 21 LEVEL ASSESSMENT QCC SKILL Level 1 2 3 4 5 GoodY HighX 5 1 3 4 2 C-1zone WORKPLACECONDITION D-1zone B zone Dzone D-2zone C-2zone C zone QCC SKILL Level 1 2 3 4 5 GoodY HighX 5 1 3 4 2 5 1 3 4 2 C-1zone WORKPLACECONDITION D-1zone B zone D-2zone C-2zone A zoneA zone Result Zone B X = 3.4 Y = 3.2 Current Zone B X = 3.0 Y = 3.0 Result : ZONE B ( Point Up ) Tanggal 22 Maret 2013 Assessor AAN DARMAWAN 714 831 600 650 700 750 800 850 BEFORE(Sep 2012) AFTER (Jan 2013) DETIK Gentan-i Stacking 1 Reduce time 117 0 25 50 75 100 before % After % SKILL & MOTIVATION UP : 5% 8 step (68%→80%) 7 tool (66%→70%) Spirit team ( 81%→86%) Tanoko (65%→73%) Before (Ave) : 69% After (Ave) : 74% COST IMPROVEMENT a. Total cost Improvement b. Cost improvement / bulan (estimasi masa pakai alat 60 bulan) a. Rp 20.001.000 b. Rp 333.350 / month COST REDUCTION c. Reduce cycle time x WH XMH 0..39 jam x 22 hari x Rp 84.000 Rp 720.720 / month BENEFIT Rp 387.370 / month Rp 4.648.440 / year
  22. 22. TMMIN-CEVD 22 8.1.STANDARISASI SOP. Mengoperasikan safety guard power less ( karakuri system ) SOP. Mengoperasikan dolly motor ( DOMO ) SOP. Mengoperasikan Hoist Stacking spring coil SOP. Proses picking spring coil ( tempel label di box ) Sosialisasi kepada seluruh member ( Red & White shift ) Date : 30 Januari 2013 Training & evaluasi proses baru kepada seluruh member Date : 30 januari 2013
  23. 23. TMMIN-CEVD 11601200 0 200 400 600 800 1000 1200 1400 Direct Indirect DETIK C. Grafik C/T Stacking   Case C6 ASSB By Process, Feb 2013 N=2360 575 625 0 200 400 600 800 1000 1200 48811-0K030 48740-0K010 DETIK D. Pareto C/Time Part Direct Stacking Case C6 ASSB, Feb 2013 -0 -50% -100%N =1200 57% 23 8.2.TINDAK LANJUT ( NEXT TEMA) F. Schedule activity QCC : Plan : Actual NO 8 STEP QCC Apr 2013 Mei 2013 Jun 2013 Jul 2013 1 PEMILIHAN TEMA 2 ANALISA KONDISI YG ADA 3 PENETAPAN TARGET 4 ANALISA SEBAB AKIBAT 5 RENCANA PENANGGULANGAN 6 PENANGGULANGAN 7 EVALUASI HASL 8 STANDARDISASI & TINDAK LANJUT 55079 54569 5456955590 0 10000 20000 30000 40000 50000 60000 70000 STACKING 1 STACKING 2 PICKING 1 PICKING 2 DETIK A. Yamazumi loading time line assy set / day, Februari 2013 Target : 50909’’ B. Stratifikasi Loading time stacking 1 by destination, Februari 2013 Destination Case type Qty case ( monthly ) Stacking timeLoading timeRank ASSB ( Malaysia ) C6 90 2360 9655 I C8 90 1526 6243 III TMP ( Philipine ) C6 82 1632 6083 V C7 82 1650 6150 IV C8 0 845 0 XII C0A 164 831 5323 VI TMV ( Vietnam ) C0 16 1560 1135 XI C6 45 2458 5028 VII C21 45 1130 2311 IX C17 45 990 2025 X C7 45 4010 8202 II C8 45 1680 3436 VIII Total 55590 E. Thema : Menurunkan Waktu Proses Direct Stacking Part no. 48811 – 0K030 Case C6 ASSB
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