Presentation Preview COST REDUCTION MARGIN IMPROVEMENT
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TPM
5S
SMED
HEIJUNKA
Inventory
Poka Yoke
$$$
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WHAT do you want?
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Current Weekly Losses
Yield Materials Losses ~ 5 Tons ~ $ 33k USD
Quality Defect ~ 3000 pcs ~ $ 11k USD
Speed Losses ~ 10 Hours ~ $ 4k USD
Stoppages Time ~ 5 Hours ~ $ 2k USD
Setup & Change over ~ 20 Hours ~ $ 8k USD
Breakdown ~ 20 Hours ~ $ 8k USD
TOTA
L LO
SS ~
66
k U
SD
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8 Pillars TPM
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QUALITY COST:Inspection & Testing.Rework, Defect, Reject & Claims.
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$A
VIN
G
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Sekumpulan
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VOLUME
COSTMaterialsLaborEnergyMaintenanceOthers
PRODUCTIVITY
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MONITORING COST PERFORMANCE
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WHY
W
H
E
R
E
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#1: Expenses
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#2: Work Inventory
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#3:Information Flow
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#4: Documentations
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#5: Work Allocations
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#6: Meeting
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WHAT??? HOW???
Global Strategy
Country Strategy
Operation Strategy
Departmental Strategy
Daily Management
Chairman’s Imperatives
Company Values
Guiding Principles
Global OperationsProcedures
Company PolicyKPI’sPMD
Quality Policy
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SASARAN STRATEGIS
KPI’sHOW? WHAT? How much?
WHO?
Monitoring
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10.3
5.9
4.5 4.1 3.9
1.5
0
2
4
6
8
10
12
Labor Utility Others Energy Maintenance Indirect Materials
Total = 30.2(Milyar Rupiah)
SAVING $100k ~ 1 Millyar Rupiah
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CHAMPION
PROJECT TEAMS
KAIZEN TEAMS
KAIZEN BLITZ WORKING COMMITTEE
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Monthly = 60’Preparing ‘ExMe’
Daily = 15’Weekly = 30’
Weekly = 30’ 1 to 1BWeekly = 45’ Team
20% Individual + 80% Team = LEADERSHIP TEAM WORKS
Tambahkan pada sisi informal. Personal Development
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Executive PresentationDocuments. Progress. Results.
Submition: – 3D
Lead by CHAMPION.Presenting by Project Owner.
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CIA No: 003/CRP/PPIC/DM/2011
Project: Meningkatkan efisiensi penggunaan
forklift
Project Description:
Pembagian tugas secara lebih merata kepada setiap
operator forklift dan kontrol speed operasional forklift yang
optimal sehingga penggunaan forklift bisa diturunkan dari 8
unit + 2 spare, menjadi 6 unit + 1 spare.
Project Owner: Wayan
Team Members: Wayan, Bowo, Budi, Sarana, Edo, Bambang
Project Start: 25 Mei 2011
Projected Finish: 05 November 2011
Planning: 05 Juni 2011
Do: 10 Juni 2011
Check: 10 Juli 2011
10 Agustus 2011
Action: 01 Oktober 2011
Cost saving & Financial impact:
Total Opportunity: IDR 212 Mio
Targeted Savings (Annual): IDR 180 Mio (on FY08)
Actual Saving ( Year to date $ ) :
YTD Aug 2007 ~ IDR 22 Mio
Accomplishments:
•Supporting Data has been collected
•Meeting XD Logistic on tracking = done
•Identify Production Mat_Hand = done
•Trucking Un/Loading Marking = done
•Financials have been established
Progress date: 30 June 2011
Diagram Block Summary
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Inspiring people on accelerating perofmance to be profitable business @TURNING LOSS INTO PROFIT