BEST PRACTICES

TQA WINNER

2006


BEST PRACTICES

TQA
Winner
2006









1
ISBN

12-15
1025 10400
0-2619-5500 630, 631, 632, 633, 636
0-2619-8086
0-2619-8085
www.tqa.or.th
tqa@ftpi.or.th
2552
978-974-638-094-2
3,000

1
2 TQM/TQA
3
4
5
6
7
8

10
18
23
30
38
45
53
64
74




. ()

.. 2549

TQC WINNER 2006 BEST

PRACTICES





. () (Rayong Gas Separation Plant
PTT Public Company Limited - GSP) .. 2521
.. 2544
(Integrated Gas Company)
. () GSP

(C2H6) LPG NGL

GSP


(TQM)

(TQA)

(Management Tools)




GSP House
GSP
Balanced Scorecard

CRM

TQA WINNER 2006 BEST

PRACTICES



GSP

MIS

Hardware, Software

(Cross Functional Team)



(Total Productive Maintenance - TPM)



GSP (Computerize
Maintenance Management System - CMMS)


GSP

TQA WINNER 2006 BEST

PRACTICES


Best
Practices

2006

. () (Rayong Gas Separation Plant PTT
Public Company Limited - GSP) .. 2521
.. 2544
(Integrated Gas Company)
. ()

GSP (C2H6) LPG

NGL



.

{ . ()}
()
(PTTCH)

GSP

TQA WINNER 2006 BEST

PRACTICES
10

1.
2.
3.

4.
5.

(QSHE)

GSP

GSP

- - - - QSHE

GSP 296 39 15

.
. .



/



TQA WINNER 2006 BEST
PRACTICES
11

273 (92%)
23 (8%)
15 (5%)
157 (53%)
99 (33%)
25 (8%)
5 (2%)
76 (26%)
215 (72%)


GSP 3 (

/) / (/)
/ /

(DCS), PMIS, SCADA

(APC)
GC Online PIMS
(SAP) ORTLOFT

Reliability Central Maintenance (RCM)

Risk Base Inspection (RBI)

Turbo Expander and Compressor, Aluminum
Plate Fin Heat Exchanger Air Cooler Hot Oil
Waste Heat Recovery Unit

46 MW 11.5 MW

CSC Internet
24

GSP .
(.) 4

(.) (.)
(.) (.)

TQA WINNER 2006 BEST

PRACTICES
12


. ()

(.)

(.)

(.)

(.)

(GSP)
(.)

(.)

(.)

(.)

(.)
(, ICT)

(.)

(.)

(.)
(.)

(.)

(.)

1 - 2 (.)

(.)

(.)

(.)

5 (.)

(.)

(.)

(.)

(.)

(.)

(.)

GSP

(.)

(.)

(.)

TQA WINNER 2006 BEST

PRACTICES
13

GSP 2

GSP

(C2H6) LPG NGL

LPG GSP

()

GSP

GSP

()

TQA WINNER 2006 BEST

PRACTICES
14

(.)

(.) LPG







GSP

()

E-mail CSC

(Customer Relation Center - CRC)

GSP LPG

7 GSP 1

GSP 3

TQA WINNER 2006 BEST

PRACTICES
15

GSP 4

1,600

3,250,000 5%

3,969,000

2% LPG

5% 2%

1.
1.
2.

3.


2.
4.

(TQA)

3.

1.
2.
3.
4.
5.
6.
7.

TQA WINNER 2006 BEST

PRACTICES
16

GSP

(QSHE) ISO/IEC17025, ISO 9001 : 2000, ISO 14001 : 2004, . 18001
/
Benchmarking
Cross Functional

:



2
5

3
5









4

TQA .. 2549

TQA WINNER 2006 BEST

PRACTICES
17

2
TQM/TQA

TQM

GSP

(TQM)


(TQA)





11 (11 Core Values)

11 3
(Strategic Leadership) (Execution
Excellence) (Learning Organization)
TQM

2.1

7

(Category) 19 (Item)

3 2.2


(Strategic Leadership) (1.1)
(1.2)
(2.1)
(2.2)
(3.1)

TQA WINNER 2006 BEST

PRACTICES
18


2 (Execution Excellence)

(6.1)

(6.2) (3.2)

(5.1) (5.2)
(5.3)

3

(Learning Organization)
(7.1) (7.2)

(7.4) (7.5)

(7.6) (7.3)
2 (4.1)
(4.2)






(Value Chain System)


11
8
6
Managing

Systems
Agility
for
Perspective
Innovation

10

1
4
5
7
Org. &
Focus on

Customer
Visionary

Personal
Focus on
Results &
Leadership
Driven
Learning
Future
Creating

Excellence

Value







2

3

9
Valuing
Social
Management
Employees
Responsibility
by Fact
& Partners

Learning Organization
Strategic Leadership
Execution Excellence

2.1 11
TQA WINNER 2006 BEST
PRACTICES
19

Strategic Leadership

1.1

Execution Excellence

Learning Organization
7.6

1.2

7.5

6.1

2.1

6.2

2.2

3.2

5.3

7.2

7.4

5.1
3.1

7.3

7.1

5.2

4.1

4.2

2.2 (1) TQA Value Chain

Vision, Mission,
Core Values, Culture,
CG, Two-way Communication
1.1

TQM, TPM, ISO, SPC, QSHE,

5S, QC, FMEA Six Sigma,
Daily Operation

7.6

1.2

7.5

6.1

2.1

2.2

Strategic Plan, SWOT, BM

BSC, RM, PA, PM
3.1

Customer Segment,
Customer Survey,
VOC

CRM, Customer Accessibility,

Customer Complaint
Customer Sat.

6.2

3.2

5.1
5.3

5.2

7.3

7.1

7.2

MIS, Info. Network, Lead /Lag KPI

HW-SW, KM, BM
4.1

4.2

Cross Team, IDP, Competency Base, Manpower,

Career Path, HRD, Employee Sat,
Internal Communication

2.2 (2) TQA Value Chain

TQA WINNER 2006 BEST
PRACTICES
20

(Management Tools)

Vision/Mission Statement
Organization : Core Values/Culture
Corporate Good Governance (CG)
Concept of High Performance Organization
(HPO) & Total Quality Management (TQM)
Two-way Communication
Coaching

Strategic Planning
Five Forces Analysis
SWOT Analysis
Balanced Scorecard (BSC)
Benchmarking (BM)
Corporate Risk Management
Performance Agreement (PA)
Performance Management (PM)

Voice of Customer (VOC)

Customer Segmentation
Customer Satisfaction Survey
Customer Relationship Management (CRM)
Customer Complaint Management
Customer Accessibility

TQA WINNER 2006 BEST

PRACTICES
21

KPI (Key Performance Indicator) :
Leading/Lagging Indicator
Management Information System (MIS) :
Production Management Information System
(PMIS), Process Information Managements
System (PIMS), Engineering Information
System (ENIS) .
Information Networking : Internet/Intranet
Hardware - Software : Enterprise Resource
Planning (ERP), Systems Applications
Products in Data Processing (SAP)
Knowledge Management (KM)
Benchmarking (BM)
Cross Functional Team
Individual Development Plan (IDP)
Competency Base Management
Performance Base Management
Career Path Management
Human Resource Development (HRD)
Employee Satisfaction Survey
Effective Internal Communication
Empowerment System
Job Rotation
On the Job Training
Intranet E-Learning
Total Quality Management (TQM)
Total Productive Maintenance (TPM)
ISO/IEC 17025, ISO 9001 : 2000,
ISO 14001, . 18001
Statistic Process Control (SPC)
Quality Safety Health & Environment Policy
(QSHE Policy)
Productivity Improvement : QCDSMEE
(Quality, Cost, Delivery, Safety, Moral,
Ethic, Environment)
Suggestion System (SS)
Quality Control Circle (QCC)
Failure Mode & Effect Analysis (FMEA)
Advance Process Control (APC)
QA Matrix/4M Analysis
Daily Operation Management

TQA WINNER 2006 BEST
PRACTICES
22

GSP
(1.1 )
(1.1 )








(Vision, Mission, Statement & Core Values)

1
1.1

1.2

(1)

(2)




(3)

(1)


(2)

(1)

(2)

.
.


(1)


(2)

TQA 1
TQA WINNER 2006 BEST
PRACTICES
23

(1)

 1
Vision, Mission, Statement & Core Values

() (-

) ()

TQA WINNER 2006 BEST

PRACTICES
24




GSP House

. .. 2545

5


Benchmarking








5
-

(1)
( )
5



(2) 2
5 (
) () (
) (
) ()

(3)
6
.



TQA WINNER 2006 BEST
PRACTICES
25


(4) 5

(5) GSP

.. 2547 .. 2548 .. 2549

3 1)

(Feed Gas) .. 2552 2)

(Plant Capacity Utilization) 3) (Total Cost)

3



(---- QSHE)




6

1



2



3

Web

4




5


6

TQA WINNER 2006 BEST

PRACTICES
26

/
//

()
6 /

. .
GSP-SPT

/Annual Report/

--
1 /
Demand


Supply

1 /

. .

GSP Intranet

1 /
GSP-SPT

1 /

GSP Intranet

1 /

. .
.

1 /

1 /

. .

Awareness .

1 /

. .

CG
GSP Intranet

1 /

. .
.

1 /

. .

. QSHEWG

JCC

JCC

. .




CSC : Customer Service Center

. .

. .

1 /

/Annual Report

/Annual Report

Good Corporate
Governance

CSC : Customer Service Center

. .

/

6 /

GSP-SPT

/

.
.


/
.


.
1 /

. .

. .
.

3.1
TQA WINNER 2006 BEST
PRACTICES
27

////
/

//E-mail///

/
3.1

/Intranet/E-mail/
/ /

1

//
(. .)

3.2

TQA WINNER 2006 BEST

PRACTICES
28

Approach

Deployment

Learning

Integration

PDCA

(TQM)

TQA WINNER 2006 BEST

PRACTICES
29

GSP
(2.2 )




(Strategic Management)
Balanced Scorecard (BSC)

2
2.1

2.2

(1)

(2)

(1) What

(2)

(1)

(2)

(3)



(4)
(5)

TQA 2
TQA WINNER 2006 BEST
PRACTICES
30

.

(1)

Strategic Management &

Balanced Scorecard (BSC)

BSC

BSC













































TQA WINNER 2006 BEST
PRACTICES
31





























Balanced Scorecard : BSC
GSP
(/

3-5 ) Demand
Supply

BSC BSC GSP

(KPI) Action Plan



GSP BSC


KPI
KPI




(Strategy Map)

GSP (Strategy Map)
4 Balanced Scorecard
Top Down Bottom Up
Top Down
TQA WINNER 2006 BEST
PRACTICES
32

 Bottom Up
BSC
(Strategy Map) 4

30%

/




/

//

/
()/

/
/

BSC GSP Strategic
Mapping Mapping

Workshop Strategic
Planning Workshop
Alignment
Bottom Up Top Down (GSP-SPT)
Trend Analysis, SWOT Analysis, Benchmarking, Financial Analysis,
Five Forces Model
TQA WINNER 2006 BEST
PRACTICES
33

(1

5 )

(Leading Indicator)
(Lagging Indicator)

BSC

Lagging KPI

Leading KPI

1.

30%
2.

/



3.

6
Risk Base
Inspection/

Plant Asset
Reliability Central Management
Maintenance
(RCM)









GC-Online

4.

/

/

- EBITDA on - ROA

Sales
- % Market Share
- Ethane Recovery
Rate
- Time Between - OP34 No. of
Turnaround
Technical Failure
- Length of
- PM & CM Ratio
Turnaround
-
(Total Cost)
- % Deviation -
Product Delivery


- -

- Market Share

TQA WINNER 2006 BEST

PRACTICES
34

-
LPG /

-

5.

6.

/

/

()

7. /

Lagging KPI

Leading KPI

Advance
Process Control
(APC)

(.)

/

Program Plant
-
- Downtime

Optimization - Product Quality
-
- Plant Capacity

Utilization

- Feed Gas

GSP6

OTS
- Training Cost

-

- Staff Index

- LTIF

-

-

-
Substandard

-

Knowledge
-
Sharing Culture

8.

Best

Practices

KM GSP
9.

-
-



(
-
)

5.


()

()

-
-
-

-
-

-


-

-

Catch Ball
Catch Ball KPI GSP-SPT
Bottom Up Two-Way Communication

TQA WINNER 2006 BEST
PRACTICES
35

 GSP
QCDSMEE
(Forecast) Action Plan

Productivity Index COACH Application

QCDSMEE KPI

(Drive) KPI

COACH Application Software
KPI KPI 3

?

?

?

Productivity Index

/

(..)

/

/

./.

/ (..)

No

/
/

./

(..)

/.

(..)

QSHEMSC

Yes
Daily Meeting
(Cross Functional)

(Contingency Plan)

(Knowledge Management)

Yes

(..)

QSHEMSC

(.. - .. )

/

()

No

4.1
TQA WINNER 2006 BEST
PRACTICES
36

QCDSMEE/
Mitigation Plan
./


BSC GSP



GSP-SPT


Balance Scorecard

Approach

Deployment

Learning

Integration

.





SWOT
Five Forces Model




BSC Catch Ball


Lead & Lag
Indicator

GSP-SPT

Quality Index :
QCDSMEE

BSC

GSP BSC

BSC BSC





KPI

QCDSMEE

TQA WINNER 2006 BEST
PRACTICES
37

GSP
(3.2 )


Customer
Relationship Management (CRM)

3.1

3.2

(1)
(2)
(3)

(1)
(2)
(3)
(4)

TQA 3
TQA WINNER 2006 BEST
PRACTICES
38

.

(1)


(2)

(3)

(4)

 3
Customer Relationship Management
(CRM)
CRM

CRM

TQA WINNER 2006 BEST
PRACTICES
39











CRM CRM (Customer
Relationship Management) GSP .. 2545

CKD (Customer Knowledge Database) CRM
CSC (Customer Service Center)

2
3





7

CSC


5 Customer Analysis, Customer

Satisfaction Analysis, Marketing & Industrial Analysis, Problem Solving Analysis, Competitor
Analysis

TQA WINNER 2006 BEST

PRACTICES
40

/

1. /
-

- /.
- .

- /.

2. (1)

- / (.)
-
GSF
- .
-
.

3. /
()

4. (2)

5. CSC/CRM
Intranet/Internet
(. CRM CSC)

6.
()

7. Daily Operation

-


-

-

- /



-

-
12
-
-
- -

-

- /
/
()
-
-
GSP
- GSP
-


-

-
- .

-




-
-

-

-

-


-

-



-

-
Operation
-

1 /

Customer Analysis

3 /
Customer
Satisfaction
Analysis

- Optimize



-

-
-

-

- /

-

-

1 /
Marketing &
Industrial
Analysis

2 /
Problem Solving
Analysis

(1) . . LPG 12

(2) .

5.1
TQA WINNER 2006 BEST
PRACTICES
41

Competitor
Analysis

CKD (Customer Knowledge Database)

5
7

Competitor Analysis

inin

gP

)
(3.2
ning

CRM

Marketing Analysis

Plan

CKD
Tra

Customer
Satisfaction Analysis

Problem Solving
Analysis

CKD

MDS

Marketing Data Server

& Plan

Customer Analysis

Marketing Strategy

CKD

lan

CKD

provement)
Im
(Process

5.2

CRM

3












TQA WINNER 2006 BEST
PRACTICES
42





CRM

/




//
Update












(.)
Operator

(Monthly)






( 2546)



( 2547)



( 2548)

( 7)





Proactive

.

.

(.)

(Quaterly)

Contact Point
GSP

.

.

5.3 CRM

TQA WINNER 2006 BEST

PRACTICES
43

Approach

Deployment

Learning

Integration

Indicator

CKD

GSP CRM

TQA WINNER 2006 BEST

PRACTICES
44

GSP

(4.1) (4.2 )


(Management Information

System : MIS)

TQA WINNER 2006 BEST

PRACTICES
45

 4
4.1

4.2

(1)

(2)

(3)

(1)


(2)

(1)


(2)


(3)


(4)

(1)

(1)

TQA 4

4
Management Information System
(MIS)

MIS

TQA WINNER 2006 BEST

PRACTICES
46

MIS








GSP-SPT
/ .

BSC


BSC

KPI

13

TQA WINNER 2006 BEST
PRACTICES
47


PIMS (Production Information Management System) DCS
(Digital Control System) ENIS (Engineering Information
System) Employee Self Service SAP (Systems
Applications and Production in Data Processing) CSC (Customer Service
Centre) CSC (Customer Service Centre)
PPS (Plant Problem Solving) ISO (International
Organization for Standardization) SAP /
SAP QSHE (Quality Safety Health and Environmental)

SCADA

Electronic Paper

1.

PIMS

Daily

2.

DCS

Real Time

3.
Drawing
Standard

ENIS

Employee

Self Service

Real Time

SAP

CSC

7.

CSC

8. Monthly & Yearly Plan

PPS

Monthly & Yearly

ISO

SAP

Monthly

. .

11. /

SAP

Real Time

12.

QSHE

Real Time

13.

SCADA

Real Time

4.
5.
6.

9. Procedure & Work

Instruction
10.

6.1 GSP
TQA WINNER 2006 BEST
PRACTICES
48





Cross

Functional Team Daily Meeting (OK)
(
)
/

GSP
SAP Executive Report
Report
- Financial Report
- Sale and Distribute Report
- Material Management Report
- Production Analyst Report

Online Monitoring

SAP System

SAP Server

PIMS, PMIS System

PIMS, PMIS Server

DCS System
- Operation Data
- Production Data

Computer

-
-

- Account Data
- Maintenance Data
- Purchasing Data Computer 2
- Human Resource
- Billing Data
- Marketing Data

6.2
GSP

Trend & Projection Analysis

Root Cause Analysis

QCC Analysis

Financial Analysis

Benchmarking

TQA WINNER 2006 BEST
PRACTICES
49

TOOL
Trend &
Projection

Analysis

SWOT
Analysis
Root Cause /
QCC Analysis
Financial
Analysis
Benchmarking

-
. .
-

. .
-

-
-
. .
. .
-

. .
. .

- EBITDA on Sales

-
-

. .
. .
. .
.

6.3 Tool

Hardware, Software



(ICT) Hardware, Software
(Network) Electronics

- ICT Backup
- Backup Daily,
Monthly Yearly

Hardware Network

- ICT Monitor
- Monthly
Uptime

Hardware

-

- Network

Network

- Backup
15
- Real Time Backup

TQA WINNER 2006 BEST

PRACTICES
50


Internet Service Provider (ISP)
1
Software Reliable

- ISP 2

- QA Software

- ICT Monitor
Helpdesk

- Real Time Backup
-

- Monthly

6.4

ICT

ICT

/





/

User/

ICT


/





ICT
ICT

ICT

ICT

Help Desk

/




ICT

ICT

6.5

TQA WINNER 2006 BEST

PRACTICES
51


Approach

Deployment

(ICT)
HW SW Network








Back up

Learning

Integration

TQA WINNER 2006 BEST

PRACTICES
52

GSP
(5.1 )



(Effective Internal Communication with Cross Functional Team)

TQA WINNER 2006 BEST

PRACTICES
53

 5
5.1

5.2

.
.

(1)


(2)



(3)

(1)

(1)

(2)


(3)



(4)

(1)

(2)

(3)



(4)


(5)



(6)

5.3
.

(1)


(2)

.

(1)

(2)

(3)
(4)

TQA 5

TQA WINNER 2006 BEST

PRACTICES
54

(1)

 5
Effective Internal Communication
with Cross Functional Team

TQA WINNER 2006 BEST
PRACTICES
55



























(Cross Functional Team)

(Cross Functional Team)

8
27

TQA WINNER 2006 BEST

PRACTICES
56


1. 4

2. 4

3. (QSHE) 7

4. 4

5. 2

6. 4

7. 1

8. (ICT) 1

( )
(

) /


(
)


(Joint
Consultation Committee : JCC)


JCC
GSP

TQA WINNER 2006 BEST

PRACTICES
57

Management Committee

TQA WINNER 2006 BEST

PRACTICES
58
M

TPM-Office
Improvement (OI)

TPM-Education & GSP

KM (Ed & KM)

GSP
KPI
GSP

QSHEWG

GSP
KPI
(.)

QSHEMSC

JCC

(.)

Plant Meeting

Responsition/

*

Y/C

GSP-SPT /

/
.
/
.

QSHEWG/
Intranet

/
.

QSHEWG

GSP-SPT

()

TQA WINNER 2006 BEST

PRACTICES
59

QSHE

/ GSP
/

TPM-Safety &
Environment
(S & E)

(.)

-//

/
/

///

TPM-Quality
Management
(QM)

Y/C

Responsition/

*

AM/./

././.

/
.

/
.

/
.

/
Intranet

/
/

.

QSHEWG
Internet

QSHEWG

QSHEWG/
Intranet

QSHEWG

()

TQA WINNER 2006 BEST

PRACTICES
60

///-/

/
/

Demand &
Supply

TPM-Planned
Maintenance
(PM)

(SAP, Daily Meeting, PPS)

TPS (SAP, Daily Meeting, PPS)

//

///

TPM-Quality
Management
(QM)

TPM-Autonomous


Maintenance
(AM)

Daily Meeting

PPS //

Responsition/

*

Daily
Meeting/PPS/
.

AM/PM/
././
../.

././
./.

PM/QM/S&E/
&
././

.

&

TPS/Daily
Meeting/.

QSHEWG

QSHEWG

/
Intranet

()

/
.

/
.

/
.

/
.

/
.

TQA WINNER 2006 BEST

PRACTICES
61

ICT

(Hardware Software Network)

GSP

Responsition/

*

FI/AM/PM/
./././
./.

AM/TPS/FI/
EM/./
./.

&

QSHEWG

()

/
.

/
.

/
.

7.1 Cross Functional Team

Flow :


: * D : M : 1 Q : 3 Y : 1 C :

TPM-Early
Management
(EM)

TPM-Focused

Improvement (FI)
Loss /
. / Loss//
()
NEW Technology



PDCA








GSP

/ GSP

GSP

.. 2528

////
/

//E-mail///

/
5.1

/Intranet/E-mail/
/ /

1

//
(. .)

7.2
TQA WINNER 2006 BEST
PRACTICES
62



Approach

Deployment

Learning

Integration

TQA WINNER 2006 BEST

PRACTICES
63

GSP

(6.1 )


(Total
Productive Maintenance : TPM)

TQA WINNER 2006 BEST

PRACTICES
64

 6
6.1
.
(1)

(2)

(3)

(4)

(5)

(6)

6.2
.
(1)

(2)

(3)

(4)


(5)

(6)

.
(1)

(2)

TQA 6

6
Total Productive Maintenance
(TPM)

3

TPM

TQA WINNER 2006 BEST
PRACTICES
65




TPM
TPM



TPM



TPM

5

TQA WINNER 2006 BEST

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(TPM)
GSP

(Computerize Maintenance Management System :
CMMS)
CMMS Plant Maintenance Module : PM Module
. (Enterprise Resource Planning : ERP)



TPM-JIPM (
Total Plant Maintenance Japan Institute of Plant Maintenance)

.. 2542



TPM-JIPM 4

A : TPM




TPM


TPM


TPM



B : TPM

TQA WINNER 2006 BEST

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C : ( 8 : P1- P8)

(P1)


8

Shut down

/


5


3


(P2)

7







(P3) 6




(P4)
6


(Self-Development)


(P5)

()


(P6) (Zero Defects)

4



TQA WINNER 2006 BEST
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(P7) 5




(P8)












D : TPM


PDCA ISO 9001 / ISO 14001 / TPM /
. 18000
Benchmarking ABB





.

TPM-JIPM 4 (15 )
A :

1. TPM

2.

3. TPM

4. TPM

5. TPM
B :

6. TPM

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C : ( 8 : P1-P8)

7. (P1)

8. (P2)

9. (P3)

10. (P4)

11. (P5)

12. (P6)

13. (P7)

14.
(P8)
D :

15. TPM

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8. Safety/Environment

3. Planned Maintenance

7. Office Improvement

2. Autonomous Maintenance

6. Quality Maintenance

5. Early Management

4. Education/Training

1. Focused Improvement

TPM 8 Pillars
P1. Focused Improvement

P5. Early Management

P2. Autonomous Maintenance

P6. Quality Maintenance

P3. Planned Maintenance

P7. Office Improvement

P4. Education/Training

P8. Safety/Environment

Example of TPM Effectiveness (KPI)

Plant Efficiency
1. OPE & OEE 80-90%
2. No. of Breakdown
- A Rank
0
- B Rank
1/10
- C Rank
1/5
3. No. of Process Failure min.
4. OPE
- Availability Rate > 90%
- Performance Rate > 95%
- Quality Rate
> 99%

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Q (Quality)
1. In-Process Failure < 1/10
2. Customer Complaint 0
3. Yield
Max.
4. Re-Processing Cost < 1/10
C (Cost)
1. Maintenance Labor Hours < 1/10
2. Maintenance Costs
< 1/5
3. Energy Consumption
- Electrical Power
- Steam
- Water
- Lubrication / Hydraulic Oil / Grease
- Sub-Material
D (Delivery)
1. Reduced Product Inventories
2. Increased Inventory Turnover Rate
3. Spare-Parts Inventories
S (Safety)
1. Number of Shutdown Accidents
- Major Accident
- Minor Accident
2. Number of Other Accidents
- Fire Accident
- Explosion Accident
3. Pollution Incidents 0
4. Man Hour
M (Morale)
1. Increased Number of Improvement Suggestion
2. Increased Frequency of Small-Group Activities (Hrs.)
3. Increased Number of One-point Lesson Sheets
4. Increased Number of Irregularities Defected
(Focus Improvement)
5. Certificate of Professional License

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Approach

Deployment

Learning

Integration

4 JIPM




8 TPM

APC, ERP,
SAP, Six sigma, FMEA,
Online analyzer

TPM

QCDSM


Daily Meeting / Cross
Functional Team



KM

TPM

TQA WINNER 2006 BEST

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6

1. GSP House

2. BSC

3. CRM

4. MIS

5. Cross Functional Team

6. TPM

(TQA)

TQA WINNER 2006 BEST

PRACTICES
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Secondment President & CEO

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3.


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4.
20,000 20,000 - 50,000 50,000 - 100,000

100,000 - 150,000 150,000

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