1. MIND MAP FINAL

MIND MAPPING

AGE ALFA NUARY (ALFA)

PERFORMANCE & CONTROL DEPARTMENT

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)

COMPANYPERFORMANCE

HOW TO START

Define Business Process

Define Flow Process

Define Jobs Mapping

Manage / Define Report

Combining Data into Summary Report

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

DE

LIVE

RY

OR

DE

R

INV

OIC

E R

ELE

AS

E PAYM

EN

T INV

OIC

E

INV

OIC

E R

ELE

AS

E

PAYMENT INVOICE

PO

RE

LEA

SE

TECH. SUPPORT

- PRODUCT DESIGN- RECEIVE ORDER- REDESIGN

FINISH GOOD

MANAGE REPORT

ALREADY NOT YET

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

DEFINE REPORTEVERY 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

DEFINE REPORT

KAIZEN : CONTINOUS IMPROVEMENT

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 Team3. To measure Factory Capacity per day (24 hours) – How much products will finish in 24 hours / day4. Will syncronize with the Planning Capacity (Timeline & Booking Capacity)

S A M P L E

MATRIX STD CAPACITY & UTILIZATION

HOUR MINUTE

TOTAL DURATION

(HOUR)

0

0

0

CATEGORY

3

1

2

DURATIONNO. ITEM CODE ITEM DESCRIPTION DIMENSION MACHINE ACTIVITY MAN POWER

TEMPLATE REPORT

REPORT RULES :1. Have to filled by Production Team per Shift and sent it to AdminTeam as a Daily Report2. The report should be submitted to the Admin no later than the end of the second shift3. 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 DIMENSIONMAN

POWERFINISH GOOD PROJECT NOTESQTY TIMES A M P L E

TEMPLATE REPORT

TEMPLATE RULES :1. Have to filled by the Admin Team after collect ing data from Prod. Team2. Information must be completed by Admin Team no later than one day after3. Admin must confirm to the production team if there is a differnces of data

DATA SUMMARYOCT'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 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 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 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

S A M P L E

PROJECT CONTROL & MONITORING DASHBOARD

PURPOSE :1. Planning Capacity to estimate produce time2. To measure “When” the Factory is Idle and ready to booked by Customers and “How Long” they have to wait until they projects are done3. To Display the Progress of Project’s Achievement by Gantt Chart

PT GRACIA KARYA MASEHI 0Project Control & Monitoring First Day of Week (Mon=2): 2

[42]

WBS Project SPK NumberTaskLead Start End Du

ratio

n (D

ays)

% C

ompl

ete

Days

Com

plet

e

Days

Rem

aini

ng

1 Exxon Mobile 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% 2 181.1.1 Wall Panel Veneer area Boardroom 1 Set 6-Oct-16 9-Oct-16 4 0% 0 41.1.2 Panel Finish AP-21 100 Lbr 20-Sep-16 22-Sep-16 3 20% 0 31.1.3 Portal Entrance 2 Unit 20-Sep-16 22-Sep-16 3 50% 1 21.1.4 Wall Panel Medium Conference Room 5 Set 20-Sep-16 22-Sep-16 3 0% 0 31.1.5 Wall Panel Meeting Room 2 Set 20-Sep-16 22-Sep-16 3 0% 0 31.2 Furniture 20-Sep-16 23-Sep-16 4 21% 0 41.2.1 Area Reception 3 Unit 20-Sep-16 23-Sep-16 4 0% 0 41.2.2 Agency 4 Unit 20-Sep-16 22-Sep-16 3 0% 0 31.2.3 Huddle Room 31 Unit 20-Sep-16 23-Sep-16 4 75% 3 11.2.4 Phone Room 1 Unit 20-Sep-16 22-Sep-16 3 0% 0 32 SKK Migas Lt. 37 203/SKK/FNT-SKK/SSP/0816 <NAME> 2-Sep-16 24-Sep-16 23 0% 0 232.1 Daun Pintu 14 Unit 2-Sep-16 15-Sep-16 14 0% 0 142.2 Skiriting 150 Btg 2-Sep-16 8-Sep-16 7 0% 0 72.3 Cornice 170 Btg 2-Sep-16 5-Sep-16 4 0% 0 42.4 Fiiling Cabinet 1 Unit 17-Sep-16 24-Sep-16 8 0% 0 8

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S A M P L E

TERIMA KASIH

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

1. MIND MAP FINAL

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