Title: Reduce COPQ by 30% in 6 months Leader: Adi Permana (Black Belt)

A3 Location: UTC Aerospace Bandung Team member: Iman D, Yana W, Wahyu, Lucky, Fian, Satrio, Budi

REPORT Date: Feb 18th, 2016 Mentor: Steve Schady (Master Black Belt)

Background: Future state & Countermesaure

COPQ cost for the line 5 is very high, the cost was around 150,000 USD per year in 2015, this situation is 1). Improvement in MSA
trigerred by many reject/defect product as well as some claim from end of customer. Product delay is 2). TPM implemented in the line
another issue resulted from this situation 3). Operators were trained in TPM, 5S & MSA
4). Regular meeting in shopfloor lead by supervisor
Current condition: 5). Quality audit in place
1). COPQ cost was 150,000 USD per year (2015)
2). Cpk is only 0.72 (<1.0) Impact
1). Reject is reduced significantly
Objective: 2). MSA is improved
1). COPQ cost is < 72,000 USD per year in 2016 3). Cpk achive 1.67
2). Cpk is > 1.3 4). Est COPQ is around 60,000 USD

Root cause analysis:

Follow up
1). Continue to measure MSA regularly (every month)
2). Measure Cpk regularly (every month)
3). Perform 5S & TPM Audit in weekly basis
4). COPQ review in daily and monthly basis