This document discusses performance management and continuous improvement in a factory setting. It describes defining business processes, flow processes, and job mappings. It also discusses managing and defining reports to combine operational data into summary reports. Templates are provided for daily production reports and data summary reports to monitor performance metrics and project timelines. The aim is to standardize reporting and continuously improve processes using the PDCA method.

1. MIND MAPPING
AGE ALFA NUARY (ALFA)
PERFORMANCE & CONTROL DEPARTMENT

2. MANAGEMENT GOAL SETTING
FACTORY
PERFORMANCE
MACHINE CAPACITY
MAN POWER CAPACITY
JUST IN TIME PRODUCTION
RM STOCK AVAILABILITY
MACHINE UTILIZATION
ZERO DEAD STOCK
ZERO INVENTORY OF FG
ZERO EMPLOYEE INCIDENT
DEPT.
PERFORMANCE
KPI (BALANCED SCORECARD)
PICA
KAIZEN (PDCA & SDCA)
COMPANY
PERFORMANCE

3. HOW TO START
Define Business Process
Define Flow Process
Define Jobs Mapping
Manage / Define Report
Combining Data into Summary Report

4. DEFINE BUSINESS PROCESS
PPIC
- CAPACITY PLAN
- MAN POWER PLAN
- SUBMIT DESIGN
CUSTOMER
- EXISTING ORDER
- NEW ORDER
LOGISTICS / WH
- RECONFIRM RM
AVAILABILITY
- CHECK RM STOCK
RATIO
PRODUCTION
- PRODUCE ITEMS
BASED ON PROD.
PLAN
- RECONFIRM
MACHINE AVB.
PURCHASING
- VENDOR
MANAGEMENT
- PO CONTROL
FIN & ACCT.
- AR & AP CONTROL
- INTERNAL AUDIT
VENDOR
SUPPLY OF RAW
MATERIAL
SPK RELEASE
PREPARE RM
PR RELEASE
DELIVERYORDER
INVOICERELEASE
PAYMENTINVOICE
INVOICERELEASE
PAYMENT INVOICE
PORELEASE
TECH. SUPPORT
- PRODUCT DESIGN
- RECEIVE ORDER
- REDESIGN
FINISH GOOD

5. MANAGE REPORT
IS THERE EXISTING REPORT TO SUPPORT THE
FACTORY’S OPERATIONAL ??

6. DEFINE REPORT
EVERY SINGLE REPORT HAS TO COMPLETED WITH THIS STEP
PDCA (PLAN – DO – CHECK – ACT)
SDCA (STANDARDIZATION – DO – CHECK – ACT)
•Learn
Process
•Gemba
DEFINE
•Time Study
•Trial & Error
MEASURE
•Analyze the
System
ANALYZE
•Develop
•Improve
IMPROVE
•PICA
•SOP
CONTROL
Standard are
created with the
employees
Carrying out the
standard (training,
practice,etc)
Compare standard
with current situation
Modify the standard
based upon the
result from checking
the standard

7. DEFINE REPORT
KAIZEN : CONTINOUS IMPROVEMENT

8. DATA NECESSARY
PURPOSE :
1. The Data of all items have been produced in the factory (should be similar with the Technical Support Data)
2. The Duration will be estimating by Production’s Team
3. To measure Factory Capacity per day (24 hours) – How much products will finish in 24 hours / day
4. Will syncronize with the Planning Capacity (Timeline & Booking Capacity)
MATRIX STD CAPACITY & UTILIZATION
HOUR MINUTE
TOTAL
DURATION
(HOUR)
0
0
0
CATEGORY
3
1
2
DURATION
NO. ITEM CODE ITEM DESCRIPTION DIMENSION MACHINE ACTIVITY MAN POWER

9. TEMPLATE REPORT
REPORT RULES :
1. Have to filled by Production Team per Shift and sent it to AdminTeam as a Daily Report
2. The report should be submitted to the Admin no later than the end of the second shift
3. Admin will inputting into the Database Template after receive the report
DAILY PRODUCTION REPORT
DATE :
MACHINE /
ACTIVITY
:
PLAN ACTUAL START FINISH
1
2
3
4
5
CREATED BY : CHECKED BY :
(WORKER / OPERATOR / SPV PROD) (SPV PROD / MGR. PROD)
NO. PRODUCE ITEMS DIMENSION
MAN
POWER
FINISH GOOD PROJECT NOTES
QTY TIME

10. TEMPLATE REPORT
TEMPLATE RULES :
1. Have to filled by the Admin Team after collect ing data from Prod. Team
2. Information must be completed by Admin Team no later than one day after
3. Admin must confirm to the production team if there is a differnces of data
DATA SUMMARY
OCT'16
DATE PROCESS MACHINE / ACTIVITY ITEM DESCRIPTION FINISH GOOD ITEM DIMENSION MAN POWER PLAN ACTUAL START FINISH HOUR MINUTE NOTES
13-Oct-16 SEMI FINISH GOOD PEMBUATAN RANGKA SOFA
13-Oct-16 FINISH GOOD FINISHING SOFA
13-Oct-16 SEMI FINISH GOOD COLD PRESS 002
13-Oct-16 SEMI FINISH GOOD COLD PRESS 003
13-Oct-16 SEMI FINISH GOOD COLD PRESS 037
13-Oct-16 SEMI FINISH GOOD COLD PRESS 038
13-Oct-16 FINISH GOOD PACKING / PACKAGING
13-Oct-16 SEMI FINISH GOOD EDGE BENDING
13-Oct-16 SEMI FINISH GOOD HINGE BOR
13-Oct-16 SEMI FINISH GOOD PANEL SAW 1
13-Oct-16 SEMI FINISH GOOD PANEL SAW 2
13-Oct-16 SEMI FINISH GOOD PANEL SAW 3
13-Oct-16 SEMI FINISH GOOD SPINDLE MOULDER
13-Oct-16 SEMI FINISH GOOD CROSS CUT
13-Oct-16 SEMI FINISH GOOD RIP SAW
13-Oct-16 SEMI FINISH GOOD HAND JOINTER
13-Oct-16 FINISH GOOD ASSEMBLY 1
13-Oct-16 FINISH GOOD ASSEMBLY 2
13-Oct-16 FINISH GOOD ASSEMBLY 3
13-Oct-16 FINISH GOOD FINISHING OUTDOOR
13-Oct-16 FINISH GOOD FINISHING INDOOR
13-Oct-16 PLANNED DOWNTIME
13-Oct-16 MFG DOWNTIME
13-Oct-16 MACHINE BREAKDOWN
QTY TIME DURATION

11. PROJECT CONTROL & MONITORING DASHBOARD
PURPOSE :
1. Planning Capacity to estimate produce time
2. To measure “When” the Factory is Idle and ready to booked by Customers and “How Long” they have to wait until they projects are done
3. To Display the Progress of Project’s Achievement by Gantt Chart
PT GRACIA KARYA MASEHI 0
ProjectControl &Monitoring First DayofWeek(Mon=2): 2
[42]
WBS Project SPKNumber
Task
Lead Start End
Duration(Days)
%Complete
DaysComplete
DaysRemaining
1 ExxonMobile QTY UNIT 200/EXM/FNT-SPK/SSP/0816 <NAME> 20-Sep-16 9-Oct-16 20 12% 2 18
1.1 Interior 20-Sep-16 9-Oct-16 20 13% 2 18
1.1.1 Wall Panel Veneerarea Boardroom 1 Set 6-Oct-16 9-Oct-16 4 0% 0 4
1.1.2 Panel FinishAP-21 100 Lbr 20-Sep-16 22-Sep-16 3 20% 0 3
1.1.3 Portal Entrance 2 Unit 20-Sep-16 22-Sep-16 3 50% 1 2
1.1.4 Wall Panel MediumConference Room 5 Set 20-Sep-16 22-Sep-16 3 0% 0 3
1.1.5 Wall Panel MeetingRoom 2 Set 20-Sep-16 22-Sep-16 3 0% 0 3
1.2 Furniture 20-Sep-16 23-Sep-16 4 21% 0 4
1.2.1 Area Reception 3 Unit 20-Sep-16 23-Sep-16 4 0% 0 4
1.2.2 Agency 4 Unit 20-Sep-16 22-Sep-16 3 0% 0 3
1.2.3 Huddle Room 31 Unit 20-Sep-16 23-Sep-16 4 75% 3 1
1.2.4 Phone Room 1 Unit 20-Sep-16 22-Sep-16 3 0% 0 3
2 SKKMigasLt.37 203/SKK/FNT-SKK/SSP/0816 <NAME> 2-Sep-16 24-Sep-16 23 0% 0 23
2.1 DaunPintu 14 Unit 2-Sep-16 15-Sep-16 14 0% 0 14
2.2 Skiriting 150 Btg 2-Sep-16 8-Sep-16 7 0% 0 7
2.3 Cornice 170 Btg 2-Sep-16 5-Sep-16 4 0% 0 4
2.4 FiilingCabinet 1 Unit 17-Sep-16 24-Sep-16 8 0% 0 8
06-Feb-17
21-Nov-16
28-Nov-16
02-Jan-17
09-Jan-17
16-Jan-17
23-Jan-17
30-Jan-17
27-Mar-17
13-Feb-17
20-Feb-17
27-Feb-17
06-Mar-17
13-Mar-17
20-Mar-17
05-Dec-16
12-Dec-16
19-Dec-16
26-Dec-16
10-Oct-16
17-Oct-16
24-Oct-16
31-Oct-16
07-Nov-16
14-Nov-16
03-Oct-16
08-Aug-16
15-Aug-16
22-Aug-16
29-Aug-16
05-Sep-16
12-Sep-16
19-Sep-16
26-Sep-16

13. ALREADY HAVE THE REPORT
FLOW OF IMPROVEMENT
LEARN THE
PROCESS
•How it was
made?
•When it was
made?
•What the
result?
FOUND THE
GAP
•What if Analyze
•Actual vs Data
IMPROVE
•Modify
•Simplify
•Accurate
STANDARDIZE
•Trial
•Documentation