weekly loss zero activity report let’s be no.1 value innovation contents 1. root cause problem...

Weekly Loss Zero Activity ReportLet’s Be No.1

Value Innovation

Contents

1. Root Cause Problem Summary

2. Root Cause Problem

Attachment : One Point Improvement

(W1 June - Root cause Problem)

Reporter : Dicky Gobel

LGEIN / SSG AV Group

2007. 06. 8

Great Company Great People LGEIN2 / 17

1. Root Cause Problem Summary

No. Area

Problem Status

PIC RemarkProgress Complete Not Complete

1. Document Part 0 11 0 Agung W

2. Logistic Part 0 4 0 Eko Irawan

3 Production Management Part 0 0 0 Ari Bowo

T O T A L 0 15 0

Summary

ITEMWeekly - June Monthly

W1 W2 W3 W4 Total Mar Apr May Jun Jul Avg

Employee (E) 25 25 25 25 25 34 33 33 25 33

Complete (C) 15 15 66 15 66

Ratio (C/E) 60% 60% 200% 200%

Progress (P) 0 0 11 0 11

Total (C+P) 15 15 77 15 77

W1 - June

Ratio Target (C/E) : 200% every month


2. Root Cause Problem

Problem List

No Date Waste/Loss Problem Issued by PIC/DIC Status

1 2 Jun ‘07 No control process for daily container manifest. Agung W Agung W Complete

2 2 Jun ‘07 Invoice number changes suddenly. Agung W Agung W Complete

3 1 Jun ‘07 Mix up Export document, Hasan Agung W Complete

4 1 Jun ‘07 No special case for paper clip. Hasan Agung W Progress

5 2 Jun ‘07 Reduce document Sending Progress report lead time Yan S Agung W Complete

6 2 Jun ‘07 Reduce Estimating Freight Cost Report lead time Yan S Agung W Complete

7 1 Jun ‘07 Daily Forecast Sales Amount progress Merah Eko Irawan Complete

8 1 Jun ‘07 No Special Monitoring Maximize Loading Container Ratio Merah Eko Irawan Complete

9 1 Jun ‘07 No monitoring for Extend Closing Anggun Eko Irawan Complete

10 7 Jun ‘07 To many document shipment by DHL for PHILLIPS buyer Haris Agung W Complete

11 7 Jun ‘07 No Grouping of Shipping Document Haris Agung W Complete

12 7 Jun ‘07 No box for keeping the stamps Widada Agung W Progress

13 2 Jun ‘07 Problems criteria to analyze main problems Anggun Eko Irawan Progress

14 2 Jun ‘07 No monitoring on DHL shipment activity Pedro Agung W Progress

15 2 Jun ‘07 Standard format report for all member Yan S Agung W Progress


Attachment 1 : Root Cause Problem (Finish Project)

◆ Loss Zero Activity ◆

Before After Quantitative Result

Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type

Problem Improvement Activity

Remark

□ Defect □ Transportation □ Over Production □ Waiting

□ Processing □ Movement □ Inventory

Model Line

AV - Sales Support GroupAV - Sales Support Group

Document Part Document Part 2-6-2007 2-6-2007

• No Control Container Manifest.• Container and seal numbers in the

System not update.

Out container evidence (P.E.) should be checked and un-match data will be updated by one person (PIC : Agung W).

Control Container Manifest

CustomClearanceCustom

Clearance

….PE flow (after)….PE flow (after)…P.E. FLOW (before)…P.E. FLOW (before)

CustomClearanceCustom

ClearanceDocument

PICDocument

PIC

Checked and update

system

Checked and update

system

Document PIC

Document PIC

By Agung WBy Agung W

Up date Data on M-System

Up date Data on M-System


Document PIC

Document PIC




Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



• Invoice number changes suddenly• No record of any changes

Changing Invoice monitoring

Should be one PIC for monitoring and recording any changes of invoices. (PIC : Agung W)

Create SI/SRCreate SI/SR **

changeschanges

* : Return M-System, Return doc to Logistic, Record changes..* : Return M-System, Return doc to Logistic, Record changes..

Record any changes of invoice, documents,

and database

Record any changes of invoice, documents,

and database

N/AN/A





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



Export Document for clearance mix up between finish documents and progress,

Export documents are separated between finish and progress documents using box file (imco).

Export Document Failing management

Organize filling documents

Organize filling documents





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



Disorder paper clips on the table - Create paper clip storage from recycled box

- Placed on the left side of table for easy movement

Paper clip Storage

Orderly, clean, and succinct place of work






Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



• 3 hours to prepare the Documents Sending Report preparation.

- Prepare The report using macro system

Reduce Documents Sending Report preparation Lead Time

N/AN/ABEFORE AFTER

3

1

Unit : hours





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



4 hours to prepare the freight estimation cost Report preparation

• Prepare The report using macro system.• 1 hours to prepare the report

Reduce Freight estimation cost Report preparation Lead Time

BEFORE AFTER

4

1

Unit : hours

N/AN/A





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line


Logistic Part Logistic Part 1-6-2007 1-6-2007

We cant estimate the sales amount in order to achieve the sales target in the 1st, 2nd, and 3rd closing.

• Modify the Production Plan Sheet by adding not only quantity progress but also amount progress daily, so we can estimate our achievement for every closing

Daily forecast sales amount progress report

Sales achievement can be monitor for each closing time

Sales achievement can be monitor for each closing time

N/AN/A





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line


Logistic PartLogistic Part 1-6-2007 1-6-2007

• Optimal stuffing not achieve because no monitoring for loading container capacity.

• Create one table to check the result of stuffing and compare it with the reference quantity of each container type.

Maximize Loading container ratio monitoring

N/AN/ABEFORE AFTER

90

95

Unit : %





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



• To high extra cost caused by Extend Closing Problems

• Create monitoring table to control the extend closing monthly and to find out the reason.

Extend Closing monitoring

BEFORE AFTER

90

30

Unit : EA/month

N/AN/A





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line


Documents PartDocuments Part 7-6-2007 7-6-2007

• PHILLIPS shipment sometimes using different Ship.Line for one destination

• Documents send by DHL separately.• DHL rate is high

• Send several PHILLIPS documents in to one shipment, in condition the gap between the sending date and onboard date not over than 4 days , and the have same destination

Combine Several documents for PHILLIPS buyer

BEFORE AFTER

175

35

Unit : USD

N/AN/A N/AN/A





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



Shipping documents are mix up between documents already receive BL, only receive draft BL, already sales, etc.

• Shipping document should groups into : • Documents with no draft & not sales• Documents with draft BL & Already

sales confirm• Original BL receive & have sent to

buyer

Grouping Shipping Documents







Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



•Stamps are disorder, •Waste time to look for when needed.•Dirty on the tables

• Box storage to store the stamps in one place• Every one who use stamp should return it to

where it belong.

Stamps storages







Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



No problem category in order to push other related dept. that cause delay on stuffing

• Separate problems in category

Landing cause problem criteria

N/AN/ACategory to find out

where the main problems

Category to find out where the main

problems





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



• No monitoring on DHL shipment Activity.• No shipment date report for buyer.

• Create daily Historical Shipment by Air waybill DHL, contain :

• No Air waybill• Invoice no• Date of shipment• destination

DHL shipment monitoring

N/AN/ADaily DHL tracing for

buyerDaily DHL tracing for

buyer





Qualitative Result

Div/Group

Area Date

TitleWaste/Loss

Type


Remark



Model Line



No competition among each Documents PIC in order to optimalization their works

• TDR team create one format of groups performance report to each PIC, contain :

• Performance of each PIC• Groups goals and achievement• Issue

Standard format for member performance

N/AN/AIncrease PIC performanceIncrease PIC performance