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Kick Off

OJD
Activity-5
(Batch #2)
BACKGROUND

HMMI president declaration regarding


HMMI
Future Production system toward 2025
Regarding Future Production
System
Towards 2025 HMMI Vision 2025
2011 - 2014 2015 - 2017(A new stage)
15MV PII・BSR Future
Activity Production
System

ConstructionMDT Cabin
of Unit PlantSix Segment
Total Demand Trend of Indonesia Commercial Vehicle The immediate
(1,000 unit/year) recovery exceed
our assumption
147 Down by half 95
from ’12

Highest 73
Record
2011 2012 2013 2014 2015 2016 2017 2019 2025
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OJD
Activity-5
(Batch #2)
Directorat Production Target
1. Management Target [ FM8J, RK8J & 130HD ]
TARGET ΣCT FY2025 ΣCT TARGET 2025 :
369310
400000 50% 60%
339765
310220 45% 48% TO IMPROVE PRODUCTIVITY
280676 39% 50%
300000 251131
32% 225279
203121 192041 40% 50% UP WITH ZERO WORK
24% 184655
200000
16%
30% ACCIDENT AND ZERO KURO
20%
100000 8% BATSU BATSU (SQA)
0% 10%
0 0%
Apr-18 FY2018FY2019FY2020FY2021FY2022FY2023FY2024FY2025

A B C * Data used : Ⓐ, Ⓚ, Ⓦ & Ⓣ


2. Reduce Kijunjikan Activity
Reduce Kijunjikan Program

A. Internal Jishuken B. Manual  Semi auto C. Automation


① Review C/T di all line ➀ Follow up genba result HMMI ➀ Identify difficult & heavy
② Memisahkan value & to HMMT before ASEAN BMC job
non value job, muda ② Follow up genba result HMMT ② Design new tools/
process to HMMI [ ASEAN BMC ] Equipment to make easy
③ Reduce non value & muda ③ HMMI genba to HMMT [ process
④ Meningkatkan line ASEAN BMC ]
efficiency ③ Introduce karakuri &
& melakukan balancing job robotic process Automation
⑤ Observation Job
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OJD
Activity-5
(Batch #2)
Kaizen Concept

KAIZEN CONCEPT
Step 0 Step 1 Step 2 Step 3
Unstable Process Visualize abnormality Kaizen 1 Kaizen 2
Eliminate Difficult job Reduce Muda Reduce Non-Value Job
(Mura, Muri)
Stable Process Kaizen Result
Muda
Reduced
Non Value
Muda Muda
Reduced
Muda

Muda

Non-Value Job Non-Value Job Non-Value Job


Non-Value Job

Value Job Value Job Value Job Value Job

Smooth Slim
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OJD
Activity-5
(Batch #2)
Spirit Kaizen
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OJD
Activity-5
(Batch #2)
DEPT. KADAI LIST
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OJD
Activity-5
(Batch #2)
ABILITY MAP

【Ability Map of Kaizen in TPS】 改善マン能力マップ


Member OJD BATCH 5
Ahmad Rondji (Log LDT)

Metode evaluasi
評価方法 Evaluation way Before Training After Training Remark
Evaluasi Evaluasi 0~5 Evaluasi 0~5
Target
・Evaluasi berdasarkan 6 tahapan Tanggal Evaluasi 15-Apr-19
 ・基本的に6段階評価 Basicaly evaluate 6 stage Basic TPS 2 3
MIFC 2 3
0:Belum pernah mendengar / tahu 7 Muda 2 3
   0:聞いたことがない Never heard of it SW 2 3
Belum pernah membaca 4M 5 Why 2 3
    読んだことがない Never read of it Kaizen Motion 2 3
Yamazumi 2 3
1:Sudah pernah mendengar / Sudah mengetahui Origami 2 3
   1:聞いたことはある I have heard it
Sudah pernah membaca Basic TPS
    読んだことがある I have read it
Ability Map 5

2:Sudah pernah melihat


   2:見たことはある I have seen it 4
Origami MIFC
3:Apakah sudah memiliki pengalaman kaizen ? 3
   3:改善の経験がある I have improved it
3
3 2
4:Apakah mampu melakukan kaizen seorang diri ? 3
   4:1人で改善が出来る I can improve it by myself 2 2 2
5:Apakah anda dapat memberikan arahan pembinaan ?
1
   5:指導できる I can teach others people

Yamazumi 2 0 23 7 Muda
3

2
2 3
Member Trainier 3 2
3
Kaizen Motion SW

Eka S Rensy / Romadhon


4M 5 Why Before Training After Training Target
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OJD
Activity-5
(Batch #2)
SCHEDULE
PT. HINO MOTORS MANUFACTURING INDONESIA Approved Checked Prepared
HINO PRODUCT INVESTIGATION DIVISION

OJD TRAINING ACTIVITY SCHEDULE (BATCH #1 FY 2019)


U Tribudi Wisnu B P Ariyanto Rensy N Romadhon N

Duration PLAN Apr-19 May-19 Jun-19 Jul-19 Aug-19 Sep-19


NO. GENERAL ACTIVITY PIC ACTUAL
(Days) W2 W3 W4 W1 W2 W3 W4 W5 W1 W2 W3 W4 W1 W2 W3 W4 W5 W1 W2 W3 W4 W1 W2 W3 W4
Plan
1. Production Div./Dept. Kadai List 5 HPID
Actual K/O M/R FINAL
Plan
2. Training in class 13 HPID
Actual
Milestone
Plan
3. Kaizen in genba 75 HPID
Actual
Plan
4. Report 3 HPID
Actual
96

DETAIL ACTIVITY 96

1 Production Div./Dept. Kadai List


Plan (8-10 Apr)
a. Confirmation kadai list to Div./Dept. Head production 3 HPID
Actual
Plan (11, 12 Apr)
b. Decided Theme & Target 2 HPID
Actual

2.1 Training in Class (Session-1) 5


Plan (15 - 16 Apr)
a. Basic TPS 2 HPID
Actual
Plan (22, 23 Apr)
b. PFT, MFC, MIFC 2 HPID
Actual

3.1 Kaizen in genba-1st (Current Condition) 4


Plan (24-30 Apr)
a. Genba check activity 5 Member
Actual
Plan (2 Mei)
b. Preparation Mieruka Board 1 Member
Actual
Plan (3 - 17 Mei)
c. Make PFT + MFC 10 Member
Actual

2.2 Training in Class (Session-2) 16


Plan (20 Mei)
a. 7 Muda + 19 View Point Kaizen 1 HPID
Actual
Plan (21, 22 Mei)
b. Standarization Work (SW) 2 HPID
Actual
Plan (23 Mei)
c. 4M + 5 Why Analysis 1 HPID
Actual

LIBUR LEBARAN
3.2 Kaizen in genba-2nd (Method/Analysis) 4
Plan (24 Mei-20 Juni)
a. Make MIFC, Current SW & Video Current Process 11 Member

LIBUR PEMILU
Actual
Plan (21-26 Juni)
b. 19 View Point Kaizen Analysis 5 Member
Actual
Plan (27 Juni-3 Juli)
c. 4M + 5 Why Analysis 5 Member
Actual

2.3 Training in Class (Session-3) 21


Plan (4 Juli)
a. Kaizen Motion 1 HPID
Actual
Plan (5 Juli)
b. Yamazumi and Balancing Job 1 HPID
Actual
Plan (8-10 Juli)
c. Origami 3 HPID
Actual
Plan (11 Juli)
d. QC 7 TOOLS 1 HPID
Actual

3.3 Kaizen in genba-3rd (Implementation) 5


Plan (12 Juli)
a. Schedule kaizen 1 Member
Actual
Plan (13-16 Juli)
b. Design Kaizen Plan 3 Member
Actual
Plan (17-23 Juli)
c. Preparation tools 5 Member
Actual
Plan
d. Kaizen Activity 29 Member (24Juli-14 Sept)
Actual
Plan (14-19 Ags)
e. Simulation 4 Member
Actual
Plan (20-23 Ags)
f. Evaluation 4 Member
Actual
Plan (26-30 Ags )
g. Socialization 2 Member
Actual
Plan (02-14 Sept)
h. Standarization 4 Member
Actual

4 Report 38
Plan (K/O 12 Juli )
a. Kick Off OJD (K/O) 1 Member
Actual
Plan (M/R 15 Ags )
b. Middle Review (M/R) 1 Member
Actual
Plan
c. Final Report 1 Member
Actual (FINAL 17 Sept )

5 HPID Check 3

Mr. Ariyanto HPID


Plan • • • • • • • • • • • • • • • • • • • •
Actual

Mr. Wisnu BP & Mr. Pribadi HPID


Plan • • • • • • • • •
Actual

96

PLAN

ACTUAL :
:
KICK OFF ACTIVITY MIDDLE REVIEW FINAL ACTIVITY
• WEEKLY CHECK HPID
Kick Off
OJD
Activity-5
(Batch #2)
MIFC CURRENT
MIFC CURRENT CONDITION SMALL PART MDW
Next
Before Process Logistic
Process
Proses Storage Setting Preparation Delivery
Loading / Storage Storage
Supplier Receiving Loading Unloading Storage Logistic 1
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
Plant

DELIVERY
5
D-1
3
D-3
Supplier
1 X /day
Kontrol stok susah di Setting part tidak
lakukan dan lama berurutan dan lama
10.00 am

Receiving Kanban log MDT


c
6
7 a 10800 detik
Part urgent
shoping list 1026 detik 11 tinggi
23 19
53 unit 28 detik 46 detik

16 detik H 15
966 detik
22 18 10 4 D-7
13 detik 53 unit 23 detik 38 detik
1 X /month
27 25 14
12 detik G 1002 detik
21 17 9
MDW 53 unit 26 detik 41 detik
1218detik
1
13 Proses supply tidak
1025 detik 14 detik F berurut dan tidak
1080 detik 36 detik 7
20 16 sesuai permintaan
26 24 8
53 unit 22 detik 12
D
13 detik 952 detik
E 24 unit

Kanban Room internal CCR


Pengechekan 2
b
part lama
04.15 pm
Penempatan part di 19 detik 111 detik
storage tercampur/tidak
standard 3 1
595 detik
SWH
6 20 unit
B
20 detik
132 detik
4 X /day 4 2
503 detik

5 A 12 unit
32 unit C
Loading / Storage Setting Preparation Delivery Storage Storage
TOTAL LEAD TIME Supplier Receiving Loading Unloading Storage Logistic 1 Total
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
c ❼ ❻ ❺ b ❹ ❸ a ❷ ❶
INFORMATION
134 782 5 28800 4320 5 5 10800 5 5 44861
27 25 23 22 21 20 19 18 17 16 11 10 9 8 6 4 3 2 1
CONVEYENCE
13 16 28 46 595 20 19 132 111 980
26 24 15 14 13 12 7 5
PROCESS
1080 1025 1026 1218 503 4852
H G F E D C B A
STAGNASI
28620 12960 17280 6480 65340

116033 Sec
LEAD TIME CURRENT 1933,88 Mnt
CURRENT 50693 65340 116033 PROSES
Total lead time
32,2314 Hour
STAGNASI 4,02892 Day
0 20000 40000 60000 80000 100000 120000 140000
SECOND
Kick Off
OJD
Activity-5
(Batch #2)
MIFC IDEAL
MIFC IDEAL SMALL PART MDW
Next
Before Process Logistic
Process
Proses Storage Setting Preparation Delivery
Loading / Storage Storage
Supplier Receiving Loading Unloading Storage Logistic 1
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
Plant

DELIVERY
5
D-1
3
D-3
Supplier
1 X /day

10.00 am

Receiving Kanban log MDT


c
6
7 a 10800 detik

shoping list 1026 detik 11


23 19
53 unit 28 detik 46 detik

16 detik H 15
966 detik
22 18 10 4 D-7
13 detik 53 unit 23 detik 38 detik
1 X /month
27 25 14
12 detik G 1002 detik
21 17 9
MDW 53 unit 26 detik 41 detik
1218detik
1
13
1025 detik 14 detik
1080 detik
F 36 detik 7
20 16
26 24 8
53 unit 22 detik 12
D
13 detik 952 detik
E 24 unit

Kanban Room internal CCR


2
b
04.15 pm
19 detik 111 detik
3 1
595 detik
SWH
6 20 unit
B
20 detik
132 detik
4 X /day 4 2
503 detik

5 A 12 unit
32 unit C
Loading / Storage Setting Preparation Delivery Storage Storage
TOTAL LEAD TIME Supplier Receiving Loading Unloading Storage Logistic 1 Total
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
c ❼ ❻ ❺ b ❹ ❸ a ❷ ❶
INFORMATION
134 782 5 500 4320 5 5 500 5 5 6261
27 25 23 22 21 20 19 18 17 16 11 10 9 8 6 4 3 2 1
CONVEYENCE
13 16 28 46 595 20 19 132 111 980
26 24 15 14 13 12 7 5
PROCESS
1080 1025 1026 100 503 3734
H G F E D C B A
STAGNASI
100 100 17280 6480 23960

34935 Sec
LEAD TIME IDEAL 582,25 Mnt
Total lead time
9,70417 Hour

CURRENT
50693 65340 116033 1,21302 Day

PROSES

IDEAL
10975 23960 34935 STAGNASI

0 20000 40000 60000 80000 100000 120000 140000


SECOND
Kick Off
OJD
Activity-5
(Batch #2)
MIFC TARGET
MIFC TARGET SMALL PART MDW
Next
Before Process Logistic
Process
Proses Storage Setting Preparation Delivery
Loading / Storage Storage
Supplier Receiving Loading Unloading Storage Logistic 1
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
Plant

DELIVERY
5
D-1
3
D-3
Supplier
1 X /day
KONTROL STOK
SETTING PART
TERVISUALISASI
BERURUTAN SESUAI
DENGAN BAIK 10.00 am
SEQ

Receiving Kanban log MDT


c
6
7 a 10800 detik

shoping list 1026 detik 11


23 19
53 unit 46 detik
TIDAK ADA LAGI PART
28 detik
URGENT
16 detik H 15
966 detik
22 18 10 4 D-7
13 detik 53 unit 23 detik 38 detik
1 X /month
27 25 14
12 detik G 1002 detik
21 17 9
MDW 53 unit 26 detik 41 detik
1218detik
1
13
14 detik PROSES SUPPLY
1080 detik 1025 detik F 36 detik 7
20 16 BERURUTAN SESUAI
26 24 8 PERMINTAAN
53 unit 22 detik 12
D
13 detik 952 detik
E 24 unit

STD STORE Kanban Room internal CCR


PENGECEKAN PART 2
TERVISUALISASI b
TERVISUALISASI
DENGAN BAIK
DENGAN BAIK 04.15 pm
19 detik 111 detik
3 1
STD STORE 595 detik
SWH TERVISUALISASI
6 20 unit
DENGAN BAIK
B
20 detik
132 detik
4 X /day 4 2
503 detik

5 A 12 unit
32 unit C
Loading / Storage Setting Preparation Delivery Storage Storage
TOTAL LEAD TIME Supplier Receiving Loading Unloading Storage Logistic 1 Total
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
c ❼ ❻ ❺ b ❹ ❸ a ❷ ❶
INFORMATION
134 782 5 28800 4320 5 5 10800 5 5 44861
27 25 23 22 21 20 19 18 17 16 11 10 9 8 6 4 3 2 1
CONVEYENCE
13 16 28 46 595 20 19 132 111 980
26 24 15 14 13 12 7 5
PROCESS
1080 1025 1026 1218 503 4852
H G F E D C B A
STAGNASI
500 500 17280 6480 24760

LEAD TIME TARGET 75453 Sec

CURRENT 50693 65340 116033 Total lead time


1257,55
20,9592
Mnt
Hour

2,6199 Day
IDEAL 10975 23960 34935 PROSES
STAGNASI

TARGET 50693 24760 75453


0 20000 40000 60000 80000 100000 120000 140000
SECOND
Kick Off
OJD
Activity-5
(Batch #2)
LAY OUT

CURRENT LAY OUT SMALL PART MD WAREHOUSE


Kick Off
OJD
Activity-5
(Batch #2)
ZOOM AREA

MAPPING MP LOGISTIC MDW SMALL PART TOTAL 14 MP

Forklift MR
Empty Pollybox

RECEIVING

1.TRIMMING PART

2. FINAL PART

SERVICE PART AREA 3. FRAME PART

4. SUB ASSY PART


Kick Off
OJD
Activity-5
(Batch #2)
GENTAN I
DOCUMENT NUMBER G/LOC/LDT/001/001
GENTAN-I PEKERJAAN
ISSUE & REVISION NUMBER
NAMA PEKERJAAN : RECEIVING EFFECTIVE DATE 19 JUNI 2019
AREA : RECEIVING SMALL PART MDW
DEPARTEMEN : LOGISTIC MDT PAGE 14-Jan
LAYOUT :
500 RECEIVING PART ATI
470' RECEIVING PART WIKA

450 RECEIVING ISI Part

RECEIVING GMU Part


400
RECEIVING PART PRCA
1
RECEIVING CSI Part
350
RECEIVING PART BERDIKARI

RECEIVING BMC Part


300
RECEIVING ASMO [DS1] Part

250 RECEIVING KTS

RECEIVING OHK & ADIKU Part

200 RECEIVING ATL & Chemco Part

RECEIVING CKPM & IRI PART


150
RECEIVING MARUGO & CAJ PART

RECEIVING AKU PART


100
RECEIVING MPI & AOP

RECEIVING DCI & BSI Part


50
RECEIVING CNC PART

0 RECEIVING PEMI / PASI


1
RECEIVING CNK PART

WAKTU ( DETIK )
No URUTAN PEKERJAAN Cycle Time Frequensi CT/Day
1 RECEIVING CNK PART 2233 1 2233
2 RECEIVING PEMI / PASI 1348 2 2696
3 RECEIVING CNC PART 1963 1 1963
4 RECEIVING DCI & BSI Part 966 2 1932
5 RECEIVING MPI & AOP 1319 2 2638
6 RECEIVING AKU PART 578 1 578
7 RECEIVING MARUGO & CAJ PART 840 2 1680
8 RECEIVING CKPM & IRI PART 1081 2 2162
9 RECEIVING ATL & Chemco Part 714 2 1428
10 RECEIVING OHK & ADIKU Part 744 2 1488
11 RECEIVING KTS 475 1 475
12 RECEIVING ASMO [DS1] Part 646 1 646
13 RECEIVING BMC Part 628 1 628
14 RECEIVING PART BERDIKARI 652 1 652
15 RECEIVING CSI Part 473 1 473
16 RECEIVING PART PRCA 720 1 720
17 RECEIVING GMU Part 940 1 940
18 RECEIVING ISI Part 707 1 707
19 RECEIVING PART WIKA 676 1 676
20 RECEIVING PART ATI 1140 1 1140

DETIK 25855
TOTAL
MENIT 430,9
PERSENTAGE
Operator Prepared by, Prepared by, Checked by,

Saya sudah membaca & mengerti ,serta akan melaksanakan dengan penuh
tanggung jawab Date : Date : Date :
Kick Off
OJD
Activity-5
(Batch #2)
YAMAZUMI

ƩLT W/H MP Ideal MP Act Eff


YAMAZUMI CURRENT
374229 28200 13,3 14 95%
MDW SMALL PART
35000

29616
30000 28548
27914 27493 27384
27306 27238 27026
25855 25456 25456
25223 25073
24641
25000

20000
Second

15000

10000

5000

0
RECEIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL 1 S/A FINAL 2 POLYBOX 1 POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
Kick Off
OJD
Activity-5
(Batch #2)
ANALYSIS VIDEO
Kick Off
OJD
Activity-5
(Batch #2)
ANALYSIS MUDA
LINE : SMALL PART MDW MP 1
Process Analysis sheet(Value, Non Value) MODEL
PROCESS
: SMALL PART
: RECEIVING
FUNDAMENTAL TPS KAIZEN VIEW POINT

Waktu manual dan mesin


Tinggi grafik C.T melebihi

Terlalu banyak supply di


pokayoke yang tidak tepat

Area part melebihi area


Repair/Pekerjaan Ulang
Beda Cycle Time di tiap

Stock melebihi yang di


NON VALUE

Ergonomi yang buruk

Tinggi grafik C.T lebih


Posisi kerja berubah-

Proses lebih dari satu


WALKING

Pengaturan dengan

Double Job/ Over


Kerja Yang terlalu
VALUE

Jarak terlalu jauh

Interfere Process
Double Handling
Kerja bolak-balik

secara bersamaan
Postur Kerja NG

rendah dari T.T


cepat/Advance
No ITEM PROSES

tidak sesuai
setiap rute
Inspection

butuhkan
model

ubah

kerja
T.T
NVW MUDA MURI MURA MUDA
DETIK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1 Jalan ke Receiving Area 580
2 Ambil Surat Jalan Yang Masuk (Di Bok DN & Surat Jalan) 1312 1551 1551
3 Jalan Ke Receiving Part 580
4 Receiving, Check Part dengan DN 8314 4210 4210
5 Jalan ke Receiving Room 580
6 Tanda Tangan Surat Jalan & Stempel 2840 1864 1864
7 Jalan ke Kanban Room 580
8 Serahkan Surat Jalan ke Member Kanban 1304 1560 1560
9 Jalan (Kembali Seperti Semula) 580

PROCESS ANALISYS

VALUE
0%

MUDA
47% NON VALUE
60%

TOTAL 0 13770 9185 2900 0 0 0 0 0 0 6074 3111 0 0 0 0 0 0 0 0 0 0 0

0 13770 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 13770 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 13770 9185 2900 12085


Kick Off
OJD
Activity-5
(Batch #2)
YAMAZUMI AFTER ANALYSIS

YAMAZUMI MP SMALL PART MDW


(ANALISA MUDA)
ƩCT L/T MP Ideal MP Act Eff

374229 28200 13,27 14 95%


35000
VALUE NON VALUE MUDA TEMACHI TAKT TIME

30000 T.T : 28200"


287 894 962 1174 707 816
2345 2976 2744 2744 3559 3127
25000

11855 15336
20000 9278 9441 15468 9556
12085 16797 9500
17301 17297
DETIK

17542 15028 17189


15000

10000
15638 16178 16015 15141 15517
13770 14280 13080
5000 11116 9764 10196 9937 9837 10087

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

DRIVER 1

DRIVER 2
S/A FINAL

S/A FINAL
FRAME 1

FRAME 2

POLYBOX

POLYBOX

F/L 1

F/L 2
TRIMM 1

TRIMM 2

FINAL
RECEIVIN
G

2
1

2
Kick Off
OJD
Activity-5
(Batch #2)
LIST PROBLEM

LIST PROBLEM SMALL PART MDW


NO AREA PROBLEM CT ILLUSTRASI 4M CATEGORY COUNTERMEASURE KEBUTUHAN TARGET REDUCE PIC DUE DATE

Mengganti receive
Proses angkat part CNC ke kategory part dari
MDW dolly transfer berat 30kg small ke Big part Follow up ke supplier terkait
1 6230 METHODE 820 5410 Rondji 21/09/2019
SMALL PART masih diangkat manual dengan mengganti metode receive terbaru
(standard 14kg) packing speck
(polybox ke dolly)

Proses angkat part


Memindahkan area
MDW PT.Meidoh ke pallet berat Follow up ke supplier terkait
2 6300 METHODE receiving dari MDW 1980 4320 Rondji 14/09/2019
SMALL PART 24 kg masih diangkat metode receive terbaru
ke SWH.
manual (standard 14kg)

Tidak ada standard store


MDW
3 /part tercampur berbagai 15216 METHODE Relay out area store Cat,masking tape,kuas 3804 11412 Rondji 07/09/2019
SMALL PART
tujuan supply

Memindahkan
Follow up ke supplier terkait
MDW Double handling proses Proses setting dan
4 105906 METHODE metode receive terbaru (22 69553 36353 Rondji 14/7/2019
SMALL PART setting dan shopping shopping ke Plant 1
supplier)
(SWH)
Kick Off
OJD
Activity-5
(Batch #2)
THEMA & SUB THEMA

Thema
BERDASARKAN PROBLEM DIATAS, MAKA KAMI MENGGAMBIL THEMA

"PRODUCTIVITY UP"
SEBAGAI PILOT PROJECT PADA OJD INDIVIDU ACTIVITY

SUB THEMA

1. Reduce ƩCT 8%
2. Reduce Lead Time
4,11 hari → 2,68 hari
Kick Off
OJD
Activity-5
(Batch #2)
TARGET

Achievement Final
Reduce CT 8%
Achievement Middle Reduce MUDA 8% Value Non Value Muda

400000
8% 10%
350000
300000 29938 37506
250000
193673 163735 156167
DETIK

200000
150000
100000
180556 180556 180556
50000
0
Current Target Achievement Final

Reduce Lead Time


LEAD TIME
CURRENT 50693 65340 116033

REDUCE 1,43 Day

TARGET 50693 24760 75453

Achievemen
t Final 32167 24760 2,09 Day

0 20000 40000 60000 80000 100000 120000


SECOND
PROSES STAGNASI
Kick Off
OJD
Activity-5
(Batch #2)
SCHEDULE KAIZEN ACTIVITY

Schedule Plan Activity


Plan Jul-19 Aug-19 Sep-19
No Activity Status Remarks
Actual Week 1 Week 2 Week 3 Week 4 Week 1 Week 2 Week 3 Week 4 Week 5 Week 1 Week 2 Week 3 Week 4

Plan
1 Design Kaizen Plan
Actual

Plan
Preparation
2
Materials
Actual

Plan
3 Kaizen Activity
Actual

Plan
4 Trial
Actual

Plan
5 Evaluasi
Actual

Plan
6 Standarisasi / SOP
Actual

Plan Actua
Kick Off
OJD
Activity-5
(Batch #2)
SCHEDULE KAIZEN ACTIVITY
PT. HINO MOTORS MANUFACTURING INDONESIA Mengetahui Disetujui Diperiksa Diperiksa Mengetahui Disetujui Diperiksa Dibuat
HINO PRODUCT INVESTIGATION DIVISION

Schedule Kaizen Activity OJD MDW Small Part U Tribudi Wisnu B P Ariyanto Rensy / Romadhon Chandra M A Ramadhani Raharjo A Rondji

PLAN
NO AREA PROBLEM ƩCT ILLUSTRASI 4M CATEGORY COUNTERMEASURE DESIGN KEBUTUHAN TARGET REDUCE PIC Harian / HOT
Jul-19 Aug-19 Sep-19 PROGRESS REMARK
AKTUAL W4 W5 W1 W2 W3 W4 W1 W2 W3 W4
Plan
I. KICK OFF ACTIVITY KE Mr.TIMBUL DAN Mr.KAZUSHI EHARA
Aktual
(K/O 22 Juli )

PLAN ( 5 - 16 Agust)
Layout area yang belum
Relayout area MDW
MDW SMALL di stadardkan sehingga cat putih dan hijau, Harian +
1
PART MP harus mencari lagi
17118 METHODE Small Part berdasarkan
Thinner, Kuas
2853 14265 A Rondji
HOT Hold 2Minggu
customernya
part yang mau di Setting AKTUAL

PLAN (19 - 23 Agust)


Belum ada adrresing Dibuatkan addressing
MDW SMALL sehingga MP harus dan disesuaikan dengan Kertas, Plastik
2 15216 METHODE 3804 11412 A Rondji Harian
PART mencari cari part yang urutan pengambilan Laminating
mau dipakai part AKTUAL

Belum Ada pengaturan


PLAN (26 - 28 Agust)
kedatangan truk
MDW SMALL Dibuatkan Schedule Kertas, Plastik
3 sehingga truck METHODE A Rondji Harian
PART kedatangan truck Laminating
menumpuk di waktu
AKTUAL
tertentu

Plan
II. MIDDLE REVIEW (50% KADAI LIST SELESAI) KE Mr.TIMBUL DAN Mr.KAZUSHI EHARA
Aktual
(M/R 29 Ags )

PLAN (2 - 4 Sept)
Level Stock MDW Masih
MDW SMALL Distandardkan ke stok 1 Koordinasi dengan
4 menggunakan stock 2 METHODE 0 A Rondji Harian
PART shift (2,5 Hari) kanban Logistic
shift (4hari)
AKTUAL

PLAN (9 - 12 Sept)
Proses angkat part ke Pemindahan destinasi
MDW SMALL dolly transfer berat 30kg part dari MDW ke SWH Koordinasi dengan
5 4261 METHODE 0 4261 A Rondji Harian
PART masih diangkat manual karena di SWH sudah supplier
(standard 14kg) memakai Tools AKTUAL

Plan
III. FINAL REPORT KE Mr.TIMBUL DAN Mr.KAZUSHI EHARA
Aktual

(FINAL 27 Sept )
PLAN : Estimasi Saving Area
ACTUAL : = 42 m² x Rp 86.000,-
= Rp. 3.612.000,- / Month

Saving cost (Reduce CT 29.938" )


= Saving 29938" x Rp 24,4 =Rp 730.495,- / Day
= Saving Rp 16.070.890,- / Month

Total Saving
= Rp 3.612.000,- + Rp 16.070.890
= Rp 19.692.890,- / Month
Kick Off
OJD
Activity-5
(Batch #2)
ILLUSTRASI KAIZEN ACTIVITY
Strategy & Kaizen Activity ( Reduce CT )
1. Pengelompokkan Part
Before
LOG
PICKING PART After
LOG
PICKING PART YAMAZUMI MP SMALL PART MDW
SA FR SA TR FN FR SUB ASSY
(Achievement)
35000
VALUE NON VALUE MUDA Reduce TAKT TIME

Contoh FRAME 30000


T.T : 28200"
TR FR TR FR FN FR
pengambil
an part S/A 2038 2038 2038 2038 2038 2038
25000
2038
15336
FINAL
SA 9817 9278 9441 15468
SA TR FN FN TR 20000 9556
12085 9500
14759

DETIK
15504 15263 15151 15259
12990
15000
TRIMMING
FN TR SA SA FR FN

10000

15638 16178 16015 15517


14280 15141
13770 13080
11116
Operator harus berjalan jauh untuk mengambil 5000 9764 10196 9937 9837 10087

part dikarenakan penempatan part di area small Mengelompokan part berdasarkan line proses, 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

part tercampur dan tidak ada standard sehingga bisa mengurangi langkah operator REC EIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL S/A FINAL POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2
1 2
F/L 1 F/L 2

REC EIVING SETTIN G POLYBOX DRIVER & FORK LIFT


penempatan yang jelas (addressing, layout, dll).
2. Reduce Level Stock
Before
FRAM

14
FRAM S/A S/A FINAL TRIM TRIM TRIM LH TRIM LH TRIM RH TRIM RH
After REDUCE AREA (3,7mx29,7)
LEAD TIME
13

12
FRAM FRAM S/A S/A FINAL TRIM TRIM TRIM LH TRIM LH TRIM RH TRIM RH
11
11

10
10
CURRENT 50693 65340 116033
RACK SPECIAL

9
RACK SPECIAL

8
8

7 7

6 6

5 5

3
4

3
REDUCE 1,43 Day
2
2

1
1

TARGET 50693 24760 75453


L7.7
L7.7
OASIS MDW (SMALL PART)
OASIS MDW (SMALL PART)

Achievement Final 32167 24760 1,38 Day


Storage Over Flow Preparation Area Storage Over Flow Preparation Area

Rack Special Temporary Storage Rack Special Temporary Storage 0 50000 100000 150000
SECOND
PROSES STAGNASI

Level Stock MDW Masih menggunakan


Distandardkan ke stok 1 shift (2,5 Hari)
stock 2 shift (4hari)
Kick Off
OJD
Activity-5
(Batch #2)
ILLUSTRASI KAIZEN ACTIVITY
Strategy & Kaizen Activity ( Reduce CT )
3. Addressing Part
Before After YAMAZUMI MP SMALL PART MDW
(Achievement)
35000
VALUE NON VALUE MUDA Reduce TAKT TIME

30000
T.T : 28200"

25000 1268 1268 1268 1268 12681268 1268 1268


15336

20000 1268 8549


9278 9441 15468
8232 8288
9954

DETIK
13491
14236 13995 13883 13991

15000 9592

10000

15638 16178 16015 15517


15141
13770 14280
13080

Belum ada adrresing sehingga MP harus Dibuatkan addressing dan disesuaikan 5000
11116
9764 10196 9937 9837 10087

mencari cari part yang mau dipakai dengan urutan pengambilan part 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
REC EIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL S/A FINAL POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
1 2

REC EIVING SETTIN G POLYBOX DRIVER & FORK LIFT

2. Pemindahan Destinasi Part MDW ke SWH


Before After YAMAZUMI MP SMALL PART MDW
(Achievement)
35000
VALUE NON VALUE MUDA Reduce TAKT TIME

Supplier MDW SWH


30000
T.T : 28200"

25000
1268 1268
2131 15336
9278 9441 15468
20000 8549 8288
8232
2130

DETIK
7823 13491
14236 13995 13883 13991

15000
7462

Supplier MDW SWH Supplier SWH


10000

15638 16178 16015 15517


15141
13770 14280
13080
11116
5000 9764 10196 9937 9837 10087

Proses angkat part ke dolly transfer Pemindahan destinasi part dari MDW ke 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
RECEIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL S/A FINAL POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
berat 30kg masih diangkat manual SWH karena di SWH sudah memakai REC EIVING SETTIN G
1 2
POLYBOX DRIVER & FORK LIFT

(standard 14kg) Tools


Kick Off
OJD
Activity-5
(Batch #2)
Achievement

Yamazumi Achievement Log MDW


Loading Time W/H Mp Ideal MP Act Eff
YAMAZUMI MP SMALL PART MDW (Current) 374229 28200 13,27 14 95%
35000 VALUE NON VALUE MUDA TAKT TIME

30000 T.T : 28200"


25000
11855 9278 9441 15336 15468
20000 12085 16797 9500 9556
DETIK

17542 15028 17301 17189 17297


15000

10000
13770 15638 16178 16015 14280 15141 15517
11116 13080
5000 9764 10196 9937 9837 10087
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
RECEIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL 1S/A FINAL 2POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
RECEIVING SETTING POLYBOX DRIVER & FORKLIFT
YAMAZUMI MP SMALL PART MDW (Achievement) Loading Time W/H Mp Ideal MP Act Eff

35000 VALUE NON VALUE MUDA Reduce TAKT TIME


336723 28200 11,94 14 85%
30000 T.T : 28200" 0
0
3306 3306 3306 3306 3306 3306 0 0
25000 1268
1268
2131 15336
20000 8549 9278 9441 15468 8288
8232
DETIK

7823 13491 14236 5436 13995 13883 13991


15000
4156
10000
13770 15638 16178 16015 14280 15141 15517
11116 13080
5000 9764 10196 9937 9837 10087
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
RECEIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL 1S/A FINAL 2POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
Kick Off
OJD
Activity-5
(Batch #2)
RESULT & BENEFIT