TPM

5S

SMED

HEIJUNKA

Inventory

Poka Yoke

$$$

WHAT do you want?

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

8 Pillars TPM

QUALITY COST:Inspection & Testing.Rework, Defect, Reject & Claims.

$A

VIN

G

Sekumpulan

VOLUME

COSTMaterialsLaborEnergyMaintenanceOthers

PRODUCTIVITY

MONITORING COST PERFORMANCE

WHY

W

H

E

R

E

#1: Expenses

#2: Work Inventory

#3:Information Flow

#4: Documentations

#5: Work Allocations

#6: Meeting

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

SASARAN STRATEGIS

KPI’sHOW? WHAT? How much?

WHO?

Monitoring

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

CHAMPION

PROJECT TEAMS

KAIZEN TEAMS

KAIZEN BLITZ WORKING COMMITTEE

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

Executive PresentationDocuments. Progress. Results.

Submition: – 3D

Lead by CHAMPION.Presenting by Project Owner.

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

Inspiring people on accelerating perofmance to be profitable business @TURNING LOSS INTO PROFIT