10. modul 10 pencapaian & penciptaan nilai kik
DESCRIPTION
TRANSCRIPT
PAGE1
MODUL 10:
PENCAPAIAN DAN PENCIPTAAN NILAI
PAGE2
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
PAGE3
PENCAPAIAN DAN PENCIPTAAN NILAI (SAMB…)
• KESAN-KESAN KE ATAS PERSEKITARAN, KOMUNITI DAN SOSIALBUKTI 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 NILAIBUKTI PENGESAHAN:BAHAGIAN KEWANGAN, JURU AUDIT, SIRIM DLL
PAGE4
CONTOH
PAGE5
18
90
10
3
1
2
5
120
60
19
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
NCL
LATHE
MILLING 1
CNC
POWER SAW
FITTING
QC
PRO
CES
S
TIME MAN
TIME MC
REDUCE PROCESS STANDARD FROM 8 TO 7 PROCESS
STD. MAKING NCM CHUCK
TIME / MINUTES
6.1 .ACHIEVEMENT AND VALUE CREATION
TANGIBLE BENEFIT
PAGE6
18
90
10
3
1
2
5
120
60
19
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
NCL
LATHE
MILLING 1
CNC
POWER SAW
FITTING
QC
PRO
CES
S
TIME MAN
TIME MC
TANGIBLE BENEFIT
IMPROVED CYCLE TIME FROM 366 MIN TO 328 MIN( 38 MINUTES )
STD. MAKING NCM CHUCK( NEW )
TIME / MINUTES
6.1 ACHIEVEMENT & VALUE CREATION
PAGE7
TANGIBLE BENEFIT
STOP NCM SETTING TIME LOST AT CUTTING SHOP
ZERO SETTINGDEFECT
1.5 HR = IS A STD. STTING TIME FOR NCM MACHINE BASE ON PIS.
129
86
125112
126 122 117
10 8 15 9 8 10 10
020406080
100120140160180200
MONTH
Output
Reject
Output 129 86 125 112 126 122 117
Reject 10 8 15 9 8 10 10
%
Sept 04 Oct 04 Nov 04 Dec 04 J an 05 Feb 05 AVE
REJECT10PCS/MONTH
6.1 ACHIEVEMENT & VALUE CREATION
SETTING TIME LOST1.5 HRS x 10 PCS =15 HOURS
ZERO DEFECT SETTING AT
NCM MACHINE
SAVING 15 HRS/MONTH
PAGE8
MATERIAL REJECT COST SAVING
(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( 271.2 + 22.5 = RM 293.7 ) X 10 X 12
= RM 35,244.00/yrNCM SETTING SAVING
STD.SETTING TIME ( PIS ) X MANAGERS RATE X EXCHANGE RATE X REJECT QTY X 12.1.5HR X 11.7 X 3.8 X 10 X 12
= RM 8,002.80/yrPROCESS IMPROVEMENT ( SAVING TIME )
PROCESS HOUR SAVING ( IMPROVE ) X MGR.RATE X EXCHANGE RATE X 1231 MINIT X 116.7 = 3618 MINIT / 60 = 60.3 HOUR60.3 HOUR X 11.7 X 3.8 = RM 2680.9 X 12
= RM 32,171.30 /yr
OTHERS CHUCK PROCESS TIME SAVING
NOTE : USD 11.7 IS A EPSON RATE ( MANAGERS RATE ) TO CALCULATE COST PER HOUR.
SLITTING SAW USAGE SAVING
AVEARAGE USAGE (MONTH) X UNIT PRICE15 X 151.65 = RM 2274.75 X 12
= RM 27,297.00/yr
TOTAL SAVING PER YEAR
A + B + C + D + E
COST INCURRED
RM317,610.00-
RM 2,145.5
QUANTUM OF ACHIEVEMENT
6.2 ACHIEVEMENT & VALUE CREATION
RM 315,464.50/yr
-
1) SMART JIG ( 6 ITEMS ) RM 1195.602) NCM SINGLE SETTING JIG RM 160.003) QC NCM CHECKING JIG RM 58.504) AMADA COOLANT RM 598.405) POWER SAW BLADE RM 133.00
TYPE OF CHUCKPROCESS HR
IMPROVEAVE. QTY /MONTH
TOTAL TIME (MIN)
BOW CUTTING CHUCK 31 min 82 pcs 2548.20
MIRROR CHUCK 20 min 222 pcs 4440.00
BUFFING CHUCK 20 min 210 pcs 4206.00
NCL CHUCK 31 min 95 pcs 2954.30
OTHERS 31 Min 322 10021.7
24170.2 / 60 = 402.8 hour TOTAL 24170.20
402.8 X 11.7 X 3.8 = RM 17910.12 X 12 = RM 214,921.4
COST OF PROJECT
PAGE9
108
15
98
1011
6
0 0
129
86
125
112
126122
106
121125
97
0
2
4
6
8
10
12
14
16
18
20
22
24
0
20
40
60
80
100
120
140
Reject Output
Reject 10 8 15 9 8 10 11 6 0 0
Output 129 86 125 112 126 122 106 121 125 97
Sept 04
Oct 04
Nov 04
Dec 04
J an 05
Feb 05
Mac 05
Apr 05
May 05
J un 05
J uly 05
REJECTQTY
(PCS)
OUTPUTQTY
(PCS)
MONITORINGDATA UNTIL
13/6/2005
6.3 ACHIEVEMENT & VALUE CREATION
RECONCILIATION OF THE TARGET
PAGE10
DATA COLLECTED DURING MONITORING
6. IMPLEMENTATION OF THE INNOVATIVE SOLUTION
16~20 MAY 16 ~ 20 MAY
16 ~ 18 MAY
Quality Monitoring At CNC Machine
Quality Monitoring At Power SawMachine
Quality Data For Off Center check
Time Study At Power Saw Machine.
PAGE11
NEW COOLANT – AMADA CUTTING SYNTHETIC SD
66% WATER BASE
ORGANIC ANTIRUST
IT CAN MOVE TO ATMOSPHEREAND SOIL ENVIRONMENT.
SAFE FOR ENVIRONMENT
SHELL TONNE OILS
ENVIRONMENT HAZARD :
Not Ready biodegradable Expected to have a high
Potential to Bio cumulate..
ENVIRONMENTAL / SOCIAL IMPACT
6.5. ACHIVEMENT & VALUE CREATION
PAGE12
NETWORKING
0
6
12
45
3
TEAM WORK
BEFORE START PROJECT
1. VERY POOR
2. POOR
3. GOOD
4. VERY GOOD
5. EXCELLENCE
6. VERY EXCELLENCE
INVOLVEMENT
PLANNINGIMPROVEMENT
EXCELLENT
2 3 4 5 60
POOR
1
Understanding the QCC concept & toolsUnderstand the technical and Engineering knowledge.
Confidence with the idea/ Suggestion givenConfidence project Will success
Commitment to the project.Commitment to group increase
Manage to enhance working Relationship with various groupHigh interactions with external QCC team.
Involvement in learning new Thing.Involvement in dealing with User/others dpt.Involvement in problem solving.
Together analysis the problemData collectionUnderstanding the group
TEAM WORK KNOWLEDGE OF QCC
CONFIDENCE COMMITMENT NETWORKING
COMMITMENT
CONFIDENCE
KNOWLEDGE OF QCC
RONI
DIANA
NORLIDAH
INVOLVMENT
BEFORE BEFOREBEFORE BEFOREBEFORE BEFOREAFTER AFTER AFTER AFTER AFTER AFTER
3 2.5
3
3 2.5
2.5
4
4
4
2.5
2.5
2.5
3
3
3
3
3
3
AVERAGE
5
5
5
5
5
56
6
6
6
66
6
6
6
5
5
5
5
3334 6 665 52.5 6
SOURCE : SURVEY FEEDBACK FROM
AFTER PROJECT
SELF- EXAMINATION
SELF ASSESSMENT RADAR CHART
KAMAL 4 4 44 445.5 5.5 5.5 6 6 6
6.6. ACHIVEMENT & VALUE CREATION
PAGE13
6.7.ACHIEVEMENT & VALUE CREATION
VERIFICATION AND VALIDATION
78
CUTTING SHOP
CUTTING MANAGER THEME COMPLETION( BUSINESS PLAN REPORT)
DEPARTMENT MGR.
CONGRATULATIONS !!!!
CONGRATULATIONS FOR YOUR ACHIVEMENT!!!
PAGE14
RESULT MONITORING AFTER IMPLEMENTATION6. IMPLEMENTATION OF THE INNOVATIVE SOLUTION
11
8
20
29
18
14
0
5
10
15
20
25
30
35
FREQUENCY
0.0050- 0.0094 0.0095 - 0.0194 0.0195 - 0.0294
0.0295- 0.0394 0.0395 - 0.0494 0.0495 - ONWARDS
LCL UCL
0.0000 0.050CLASSES BOUNDRY
RANGE OFTHE PRODUCT
CHECK ITEMS : INNER SITTING DIAMETER VS TOP PROFILE.NO. OF SAMPLE : 100PCS.
NAME OF PRODUCT : NCM CHUCK
HISTOGRAM – OFFCENTER CHECK
6
13
37
20
15
6
0
5
10
15
20
25
30
35
40
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 atas
UCL
46.0000 46.0200
LCL
RANGEOF THE PRODUCT
CLASSES BOUNDARY
ONWARDS
CHECK ITEMS : INNER SITTING DIAMETER
HISTOGRAM OF INNER SETTING DIAMETER.
FR
EQ
UE
NC
Y
46.000 - 0.000+ 0.020
RANGE OF THEPRODUCT
NAME OF PRODUCT : NCM CHUCK
NO. OF : 100PCS.
HISTOGRAM
NORMAL DISTRIBUTIONUNDER CONTROL.
PAGE15
54 4
7
5 56
3
0 0 0 0 0
52
61
53
72
5256
70 71 70
65
7068
62
0
2
4
6
8
10
12
14
16
18
20
22
24
0
10
20
30
40
50
60
70
80
Reject Output
Reject 5 4 4 7 5 5 6 3 0 0 0 0 0
Output 52 61 53 72 52 56 70 71 70 65 70 68 62
Sept 04
Oct 04
Nov 04
Dec 04
J an 05
Feb 05
Mac 05
Apr 05
May 05
J un 05
J uly 05
Aug 05
Sep 05
Oct 05
REJECTQTY
(PCS)
OUTPUTQTY
(PCS)
MONITORING RESULT AFTER IMPLEMENTATION
10. REVIEW & CONTINUOUS IMPROVEMENT
RESULTUNTIL AUG.05
PAGE16
10
4.7 4.2 4 3.52.3
34.8
51.2
65.9
79.8
92.0
100
02468
10121416182022242628
NC
M C
HU
CK
OFF
SE
T
BU
FFIN
G/M
IRR
OR
CH
UC
K R
EJ.
PU
NC
H/D
IED
ELA
Y
CU
TTE
RB
RO
KE
ND
CO
VE
RIN
G J
IGW
EA
R O
FF
MA
TER
IAL
CR
AC
K
PROBLEM
RE
J.Q
TY
0
10
20
30
40
50
60
70
80
90
100
REJECT QTY ACC
54
3 32
002468
10121416182022242628
PU
NC
H/D
IED
ELA
Y
CO
VE
RIN
G J
IGW
EA
R O
FF
CU
TTE
RB
RO
KE
ND
MA
TER
IAL
CR
AC
K
BU
FFIN
G/M
IRR
OR
CH
UC
K R
EJ.
NC
M C
HU
CK
OFF
SE
T
PROBLEM
RE
J.Q
TY
REJECT QTY ACC
BEFORE AFTER
AVERAGE REJECT / MONTH
PARETO GRAPH – BEFORE AND AFTER
PROJECT
30
20
0
10
80
5060
40
70
10090
%
29.4
70.5
88.1100
52.9
REJECT DATA MAY 05
100%ELEMINATE NCM CHUCK OFFSET