SMALL GROUP ACTIVITY

BRAVO

PT.Sinyotama IndustriP. Rod

Topic :Reduce Scrap Over Sanding

From Rp. 1,913,344 to Rp. 451,182Period February - April 2008

Motto :

Fasilitator Group Leader Assit Leader Secretary

Soni W Hotmian S Gustina Siregar Karyani

Together For A Success

STRUCTURE OF ORGANIZATION

1. Iqbql G 8. Mira W 15. Fuat

2. Torius H 9. Tanti Q 16. Zunaidin

3. Fitria E 10. Rina M 17. Ali K

4. Widy V 11. Paryati 18. Maripan

5. Sigit P 12. Jerni H 19. Tika A

6. Sudarno 13. Desra W 20. Gunawan

7. Yusuf W 14. Anton

Members :

Step 1DEFINE

PROBLEM DEFINITION

From Pareto Chart We can see focus of

Improvement on our project

is Over Sanding

Focus Improvement

NO Nc Item Nov-07 Des-07 Jan-08 Average

1 Over Sanding Rp. 1,085,889 Rp 2,042,406 Rp 2,612,038 Rp 1,913,344

2 Broken Rp 105,642 Rp 2,025,652 Rp 2,323,465 Rp 1,484,920

3 Crack Rp 1,879,873 Rp 1,025,642 Rp 1,208,490 Rp 1,371,335

4 Material take out Rp 986,856 Rp 586,423 Rp 958,426 Rp 993,767

PARETO DIAGRAM LAST 3 MONTH DATA

PROBLEM DEFINITION

Over Sanding is :• This Nc has because blank stoped on sanding process with sanding belt.

Effect:• Hight Scrap

• Many additional to M.Rod

• Shipment delay

Sample Over Sanding

Step 2MEASUREMENT

BACKGROUND (LATAR BELAKANG)1. LAST THREE MONTHS DATA

Description Nov-07 Des-07 Jan-08 Total Average

Prod.Qty 29,358 28,546 35,245 93,149 31,050

Scrap total (Rp) Rp4,057,557 Rp5,950,123 1085 Rp17,110,098 Rp5,703,366

Scrap Over sending(Rp) Rp1,085,589 Rp2,042,406 Rp2,612,038 Rp5,740,033 Rp1,913,344

% Scrap Over sending 27% 34% 37% 98% 33%

The disadvantage of problem to production result.

1.SOT Not Achieve.

2.Customer wos not satisfied.

3.Many hidden factory.

BACKGROUND (LATAR BELAKANG)

100%

42%

58%

Base on data line NC :

1. Highest scrap over sanding on Jan-08 : Rp 2,612,038.= 100%2. Lowest scrap over sanding on Nov-07 : Rp 1,085,589 = 42%3. Percentage reduce scrap over sanding is = 100% - 42% = 58%4. Possibility Reduce scrap over sanding from lowest is : =Rp 1,085,589 - Rp 1,085,589 (58%) = Rp 1,085,589 –Rp 1,085,589 =

Rp.451,182.-5. Reduce Scrap over sanding our target is =Rp.451,182.-

Rp. 451,182

Achive plan Target is :

This setting Target with agree by our Manager :

Mr.Chinpen

This setting Target with agree by our Manager :

Mr.Chinpen

2. TARGET ACHIEVEMENT

BACKGROUND (LATAR BELAKANG)

2.7. RENCANA JADWAL KEGIATAN DENGAN METHODE GANTT CHART

MonthS/N Week 0 0 1 2 3 4 5 6 7 8 9 10Day of Mtg Sun Sat Sat Sat Sat Sat Sat Sat Sat Sat Sat Sat

8-F

eb-0

8

15-F

eb-0

8

22-F

eb-0

8

29-F

eb-0

8

14-M

ar-0

8

28-M

ar-0

8

4-M

ar-0

8

4-A

pr-0

8

11-A

pr-0

8

25-A

pr-0

8

Sch 0.5

Res 0.5

Sch 0.5

Res 0.5

Sch 1

Res 1

Sch 1

Res 1

Sch 1

Res 1

Sch 2

Res 2

Sch 2

Res 2

Sch 0.5

Res 0.5

Sch 0.5

Res 0.5

AKTIVITAS

Ste

p

PH

AS

EC

ON

TR

OL Standarisasi Document & Socialization

9 Follow Up Action

7

1 Problem Definition

2

Identifikasi akar masalah ( Fishbon Chart )

5

4

Pengembangan & Pemilihan Solusi( Tree Diagram )

6

Feb-08 Mar-08 Apr-08

DE

FIN

E&

ME

AS

UR

E

8

Hasil & Review

Measurement & Bacground data

Verifikasi akar masalah ( C&E Matrix )

IMP

RO

VE

Penerapan & Review

3

AN

ALY

ZE

This is our schedule activity has effective

SCHEDULE ACTIVITY

Step 3ANALYZE

IDENTIFY & VERIFICATION OF PROBABLE COUSES

Diciplin

Lazy

1. To less Responsibility

To Less Konsentrasi

2. Wrong processNew Manpower

3. To less training

To Less skill

To less Ask

4. No follow WI & DrawingLikes Sending

5. Nothing Standard sending

Blank Incoming

6. Nothing QC Incoming

No check

Sending/buffing Belt

Quality No good

7. Easy broken off

Method Machine

ManMaterial

Why Scrap Over

Sending?

Tier

Often leak

Use lakban

8. Use cutter of cut

Setting belt no stndard

9. Sending is shakySeater blank

Easy moved

12. Setting No fix

11. Key lock not pass

Easy shaky

Pushed is strong

10. Tier is stoped

Base on braistorming with fishbone chart, we have 12 possibility root couse.


1. C & E MATRIX DIAGRAM

Rating of importance to costomer internal/external 6 10 4 6

STEP 1A B C D

Reduce DLNC Reduce ScrapReduce cycle

timeHight

costumer claimTotal

NONONo & Name Top3

4MKemungkinan Akar Masalah dari fish bond chart

1 MAN To less Responshibility 9 9 1 1 1542 MAN Wrong process 9 4 1 1 1043 MAN To less training 9 1 1 1 744 MAN No follow WI & Drawing 9 9 1 1 1545 Methode Setting No fix 4 4 9 1 1066 Methode Key lock not pass 4 4 9 1 1067 Machine Easy broken off 4 4 4 1 868 Machine Use cutter of cut 4 4 1 1 749 Machine Sending is shaky 4 4 9 1 10610 Machine Tier is stoped 4 4 1 1 7411 Material No standard sending 4 4 1 1 7412 Material Nothing QC incoming 1 1 1 1 4

Proses inputs


2. C & E MATRIX DIAGRAM

Rating of importance to costomer internal/external 6 10 4 6

STEP 2A B C D

Reduce DLNC Reduce ScrapReduce cycle

timeHight

costumer claimTotal

NONONo & Name Top3

4MKemungkinan Akar Masalah dari fish bond chart

4 MAN No follow WI & Drawing 9 9 1 1 1541 MAN To less Responshibility 9 9 1 1 1545 Methode Setting No fix 4 4 9 1 1066 Methode Key lock not pass 4 4 9 1 1069 Machine Sending is shaky 4 4 9 1 1062 MAN Wrong process 9 4 1 1 1047 Machine Easy broken off 4 4 4 1 868 Machine Use cutter of cut 4 4 1 1 743 MAN To less training 9 1 1 1 7410 Machine Tier is stoped 4 4 1 1 7411 Material No standard sending 4 4 1 1 7412 Material Nothing QC incoming 1 1 1 1 4

Proses inputs

After make analyze with C & E Matrix we found five root problem to cause over sanding , material very high until three month ago.


3. Proportion root cause by Pie Chart

DESCRIPTION POINT PERSENTASE

MAN 308 49.2%

METHODE 212 33.9%

MACHINE 106 16.9%

MATERIAL 0 0%

TOTAL 626 100%


4. ROOT CAUSES

4.1. No Follow Work Instruction 4.2. To less responsibility

Problem Faced :

1. Never audit by leader

2. Knowledge no enough

3. Many Scrap

Problem Faced :

1. Lazy to checking

2. Work to less focus

3. Many Scrap


4. ROOT CAUSES

4.3. Setting No Fix 4.4. Key Lock Not Pass

Problem Faced :

1. Loose time for setting

2. Landscape is shaky

3. Tier is shaky

4. Effect Scrap

Problem Faced :


2. The use base of blank is shaky

3. Tier is stoped

4. Effect Scrap


4. ROOT CAUSES

4.5. Sending is shaky

Problem Faced :

1. Blank Wave

2. Blank of pinshed

3. Effect Scrap

Step 4IMPROVE

RECOMMENDE SOLUTION

TREE DIAGRAM

Topic

We choose alternative with high score as good solution into root problem finished.

RECOMMENDE SOLUTION

TREE DIAGRAM

No Root Problem Control Alternatif solution Advantage

1 No follow WI & Drawing Visual Made a Place Drawing & WIEasy manpower in to made understanding about WI

2 To less Responsibility Visual Focus with jobs To less scrap from skill manpower

3 Setting No fix Visual Maintanance made monitoring check list

To less scrap from machine

4 Key lock no pass Visual Modifikation by maintanance Made care about machine

5 Sending is Shaky Visual Made lakban back sanding belt To less scrap from sending belt

This is a comparison between root problem with our alternative to taken for definite indeed our solution very effective for finished this problem

IMPLEMENTATION

4. Activity Program

No Activity Date activity

P.I.C Min 2 person

Activity status (Complete Delay,Postpone )

01 Made a Place Drawing & WI01 Maret 2008 08 Maret 2008 Darman & Jono

Ok

02 Focus with jobs29 Pebruari 2008

29 Pebruari 2008 Tina & Hotmian

Ok

03 Maintanance made monitoring Check list

29 Pebruari 2008

29 Pebruari 2008 Darman & Jono

Ok

04 Modifikation by maintanance01 Maret 2008 14 Maret 2008 Darman & Jono

Ok

05 Made lakban back sanding belt29 Pebruari 2008

29 Pebruari 2008 Tina & Hotmian

Ok

This is a implementation we makes with accept times & schedule

IMPLEMENTATION

4. ACTION

1. Made a Place Drawing & WI

Problem Faced :

1. Difficult to knowledge

2. Knowledge no enough

3. Many Scrap

Advantage:

1. Easy Manpower for understand

2. Increase knowledge manpower

3. Reduce over sending

Before SGA After SGA

IMPLEMENTATION

4. ACTION

2. Focus with jobs

Problem Faced :

1. Lazy to checking


3. Many Scrap

Advantage:

1. Easy manpower for know

2. Update for skill


IMPLEMENTATION

4. ACTION

3. Maintanance made monitoring Check list

Problem Faced :

1. Never audit

2. Long time for order repair

Advantage:

1. Easy Manpower for monitoring

2. Increase quickly for repair.


IMPLEMENTATION

4. ACTION

4. Modifikation by maintanance

Problem Faced :


2. Used a key lock “L” for setting

3. Tier is stoped

4. Effect Scrap

Advantage:

1. Easy Manpower for setting


3. Reduce over sending


IMPLEMENTATION

4. ACTION

5. Made lakban back sanding belt

Problem Faced :

1. Lazy to checking


3. Many Scrap

Advantage:

1. Easy Manpower for setting


3. Reduce over sanding


RESULT

5. Weekly Result

DESCRIPTION

Last three month Pebruary 08 Maret April

Nov-08 Des - 07 Jan-08 Week 1 Week 2 Week 3 Week 4 Total Week 5 Week 6 Week 7 Week 8 Total Week 9 Week 10 week 11 Week 12 Total

Prod. QTY 29,358 28,546 35,245 34291 35783 47109

Scrap total Rp. Rp4,057,557 Rp5,950,123 Rp7,102,419 Rp2,812,258 Rp937,419 Rp937,419 Rp937,419 Rp5,624,516 Rp2,293,874 Rp764,625 Rp764,625 Rp764,625 Rp4,587,748 Rp1,810,739 Rp603,580 Rp603,580 Rp603,580 Rp3,621,478

Scrap over sending Rp1,085,589 Rp2,042,406 Rp2,612,038 Rp341,994 Rp280,665 Rp180,665 Rp280,665 Rp1,083,988 Rp318,517 Rp306,172 Rp306,172 Rp306,172 Rp1,237,033 Rp306,314 Rp468,771 Rp368,771 Rp468,771 Rp1,612,627

% Scrap Over sending 27% 34% 37% 12% 43% 42% 41% 19% 14% 53% 51% 40% 27% 4% 78% 1% 1% 45%

Average Scrap Over sanding

33%

35% 39% 21%

30%

47109

RESULT

5. Comparetion

Before SGA During SGA

DESCRIPTIONLast three month Last three month

% ImproveNov-08 Des - 07 Jan-08 Pebruary 08 Maret 08 Apr-08

Prod. QTY 29,358 28,546 35,245 34,291 35,783 47,109

2%

Scrap total Rp. Rp5,606,049 Rp9,231,518 Rp14,233,322 Rp8,895,292 Rp4,587,748 Rp946,823

Scrap over sending Rp1,085,589 Rp2,042,406 Rp2,612,038 Rp1,083,988 Rp1,237,033 Rp1,612,627

% Scrap Over sending 27% 34% 37% 19% 27% 45%

% Average before & After 33% 30%

Step 5CONTROL

STANDARIZATION

Status Perubahan

Beri tanda tick di kolom yang ada

Nama Dokumen Nama Dokumen No Dokumen

Revise/New/Discard

Tanggal Completed

Prepared by

DIC / Mgr Approved

by

Tanggal Efektif

7.1 WI 7.2 PCP 7.3 Lay Out Man 7.4 Lay out Process

7.5 MC Capability 7.5.1 MC _________ 7.5.2 MC _________ 7.5.3 MC _________ 7.6 R&R Result form 7.6.1 R&R Inspektor 7.6.2 R&R Man 7.6.3 R&R M/C 7.6.3 R&R Gauge 7.7 TPM Form 7.7.1 MC _________ 7.7.2 MC _________

7.7.3 MC _________

7.8Quality Record 7.8.1 7.8.2 7.8.3 7.9 Prosedur Made Work Drawing place 28 Maret 08 Zuhry Hanafi 1-Apr-08 7.9.1 Form Monitoring Scrap 28 Maret 08 Soni Hanafi 1-Apr-08 7.9.2 7.9.3

7.1 Cheeksheet 7.10.1 7.10.2 7.10.3

1. Standarrization Form

FOLLOW UP

2. Standarrization Form Monitoring

FORM MONITORING SCRAP FISHING ROD

DATE MODEL QTY NC ITEM NC BY CHECK BY

1). Form Monitoring Scrap 2). Made check list machine

There are two form monitoring at follow up, during that after SGA

This is Cost saving we got reduce with average three month is Rp.1,806,385

Has active of SGA

COST SAVING

MONTH

Data three month ago Data project activity

Nop-07 Des-07 Jan-08 Feb-08 Maret-08 Apr-08

RESULT 29,358 28,546 35,245 34,291 35,783 38,399

Scrap over sending Rp 1,085,589 Rp 2,042,406 Rp 2,612,038 Rp1,083,988 Rp1,237,033 Rp1,612,627

Cost Average Rp1,913,344 Rp1,311,216

Average cost a month saving, that is Rp602,128

Average cost a year saving, that is Rp7,225,540

4.1.TANGIBLE BENEFIT

1. Made good level to take notice official about over sanding

2. Made good level for teamwork between member Under Coat

3. Made good level for education in makes data analyze 4. Made good level for skill in to operational computer5. Made good level to made report and percentage

4.2. INTANGIBLE BENEFIT

• Reduce Scrap Over sanding from

Rp1,913,344 to Rp1,311,216

• To less DLNC from 3 % to 2%

• Cost Saving / three month Rp.1,806,385 .-

NEXT PROJECT

END PRESENTATION

SMALL GROUP ACTIVITY

Documents

Transcript of SMALL GROUP ACTIVITY