FORUM MANAGEMEN

TKMPN XXIII
SOLO, 19 NOV 2019
IMPLEMENTATION KAIZEN CULTURE
in
PT. AMERTA INDAH OTSUKA
 SPEAKER PROFILE
Tema : Kaizen Culture Development

Mr. Wheny Utoyo, SSi, Apt, MM

Curriculum Vitae
1. Plant Manager - PT Amerta Indah Otsuka – Sukabumi Factory – Food & Beverage (2015 – Current)
2. Head of QC & MR ISO - PT Amerta Indah Otsuka - Food & Beverage (2011 - 2014)
3. Plant Manager – PT Amerta Indah Otsuka – Kejayan Factory – Food & Beverage (2009 – 2010)
4. Head of QA, GMP & Regulatory Affairs - PT Otsuka Indonesia - Pharmaceutical (2005 - 2008)
5. Head of QC - PT Otsuka Indonesia - Pharmaceutical (2000 - 2004)
Otsuka-people creating new products
for better health worldwide
 OTSUKA BUSINESS UNIT WORLDWIDE

OAI OPEL
(Otsuka America Inc.) (Otsuka Pharmaceutical Europe Limited)

OAI CIL OPUK OPSA

Ridge OAPI OPFS Otsuka
Pharmavite OMRI OPEL Scandinavia OPC
CGW Meretek ( Otsuka Pharmaceutical)
OPGmbH
CGRW OPDC
Soma Bev Galenia
OIAA
Tokyo
(Otsuka International Asia Arab) Osaka
Dong-A Otsuka Tokushima
China Otsuka Korea OIAA
Guangdong Otsuka Tianjin Otsuka Beverage
Xuzhou VV Food & Bev Zhejiang Otsuka
Otsuka Guangdong Bev.
Otsuka HK
Taiwan Otsuka
Thai Otsuka
Egypt Otsuka PT. Otsuka Indonesia
Otsuka OPV Korea Otsuka PT. Widatra Bakti
Otsuka Pakistan Shanghai Holding
King Car Otsuka PT. Merapi Utama Pharma
Sichuan Xicheng Otsuka
Otsuka Beijing Res,Inst Micro Port Medical Shanghai PT. Otsuka Jaya Indah
Otsuka Saha-Asia Research Otsuka Philipines. PT. Amerta Indah Otsuka
 PRODUCTION FACILITIES
Name Sukabumi Factory Name Kejayan Factory
Location Sukabumi, West Java
Location Pasuruan, East Java
Land Area 220,000 m2
Land Area 135,258 m2
Building Area 63,000 m2
Building area 61,476.36 m2
Operation February, 2004
Sukabumi, Jawa Barat Operation November, 2009
15 gr sachet
37 gr Sachet PET 350 mL
330 mL CAN
PET 500 mL
PET 350 mL
PET 900 mL
PET 2000 mL
SOYJOY
Oronamin C
Total Employee 437 employee Pasuruan, Jawa Timur Total Employee 273 employee
 OUR PRODUCT

2007
PET 350 mL
1989 SOYJOY Mango Coconut 2010
2001 2006 2008 PET Aseptic
CAN 330 mL SOYJOY Apple l SOYJOY Raisin Peanut
Sachet 15 gr PET 500 mL PET 2000 mL
SOYJOY Hawthorn Berry 500 & 350 mL

2015
2014 SOYJOY 2018
2010 2012 SOYJOY Banana Almond & Chocolate 2016 Oronamin C &
SOYJOY Strawberry PET 900 mL SOYJOY Peanut IONESSENCE 250 mL Sachet 37 gr SOYJOY
OPEN FACTORY
FACTORY VISIT SUKABUMI FACTORY VISIT KEJAYAN

Total visitor: Total visitor:

277,027 129,182
(Feb’08 - Aug’19)
(May’10 – Aug’19)
DISTRIBUTION ROUTE

HONGKONG
MYANMA
R
VIETNAM TAIWAN

MIDDLE EAST
BANGLADESH

MALAYSI PHILIPINE
A

SINGAPOR
E

TIMOR LESTE
MANAGEMENT SYSTEM
OHSAS 18001:2007
FSSC 22000 Health and Safety
Food Safety System Management System
Certification

ISO 9001:2015 ISO 14001:2015

Quality Management Environment
System Management System

HALAL ISO 50001

Assurance Energy Management
System System
COMPANY PRINCIPLE
 SCOPE DEVELOPMENT
R&D
Research & Development
For new product
development.
From Scientist, formulator,
and top management.
Technical Development
For New SKU, New Line, Kaizen
New Machine, New For people development
Production Facility, New Idea for Improvement
Technology. and analytical thinking &
From top management. continuous
Improvement.
From employee.
WHAT KAIZEN DO

EMPLOYEE DEVELOPMENT BY KAIZEN

• Awareness
• Skill
• Knowledge
How to Increase
• Creativity
• Responsibility
• Team work
• Sense of Belonging
GENERAL MILESTONE OF KAIZEN IMPLEMENTATION
PT. AMERTA INDAH OTSUKA

1. High Resistance From Employee 3. Changing Mind Set

Extra effort building employee motivation. Not only focus on Quantity Idea but
Use reward and appreciation focusing on Quality Idea that have several
Need Education to employee benefit category.
Quantity oriented

PHASE 1 PHASE 2 PHASE 3 PHASE 4

2011 – 2013 2014 – 2016 2017 – 2019 2020-2024
Building Follow PDCA / Quality Change &
Awareness DMAIC Concept Improvement External Benefit

2.Education Method Problem Solving 4. Plan for go Inovation

Propose join international convention to
Held training to Employee, Facilitator, Dept
prove capability team member and increase
Head and Management for Method Problem
company image.
Solving will be applied
 PHASE 1

2011 – 2013
Building
Awareness
PHASE 1
1. MANAGEMENT COMITMENT
Kaizen Declaration:
23 Mar 2013
All level committed to implement Kaizen
PHASE 1

2. Establish Kaizen Committee

2nd Kaizen Committee 2013 1st Kaizen Committee 2012

TRAINING

TRAINING ALL AMPLOYEE:

Participant for IFI: Staff- Sr. Staff
Participant for GKM: Staff- Sr. Staff-SPV

Training for educate and building awareness of Kaizen mindset to all employee
PHASE 1

3. Giving reward (souvenir) to creator idea

Kaizen Event 2013 Giving Reward to Creator Idea

Creator Idea Submit form Idea Idea Give Day

CAMPAIGN KAIZEN

Visualization and
recognition:
Recognition deliver by Superordinat
in frame of Improvement
visualization.

Gimmick & Souvenir:

- Gimmick are seasonal
-Souvenir Kaizen provided base on Poin
accumulation

Tematic Gimmick & Poin Souvenir

Phase 1

4. Simplify of Mechanism Idea

KAIZEN SYSTEM

“IDEABOX” APPLICATION SYSTEM”

AIO Internal Application Web Base

Idea Input from idea creator
PHASE 1

Problem:
1. Employee confuse what idea should submitted.
2. Low employee participation.

Action:

1. Free idea type (not specified idea type).

2. Training employee (theme: creative & innovative thinking).
3. Campaign Program Kaizen and publish employee achievement

Training Creative & Innovative Thinking

 PHASE 2
2014 – 2016
Follow PDCA / DMAIC
Concept
PHASE 2

1. Use method PDCA & DMAIC to follow the right step rules
2. Train the employee to thinking with the data

Train method DMAIC

PHASE 2

Problem:
Medium ability to use the method

Action:

1. Coaching team ATCI

2. Organize Internal convention for ATCI & join external convention

Internal Convention 2014 BOD Appreciate the Winner ATCI team

 PHASE 3
2017 – 2019
Quality Improvement
PHASE 3

1. listing problem to be solved that highlight by

company

Offering List Problem in Dept Head Forum Discussion

TRAINING

TRAINING FACILITATOR:
Facilitator for IFI: SPV up
Facilitator for GKM: Level M1 up

Training Facilitator Improvement (level supervisor up)

to build awareness and motivate sub ordinate
PHASE 3

2. Change category the winner into category of quality

achievement (bronze, silver, gold, platinum, diamond).
2019
Improvement Level Category

BRONZE SILVER GOLD PLATINUM DIAMOND

(60-60,9) (70-78,9) (79-86,9) (87-93,9) (94-100)
•According to •Align with •Benefit for •Benefit for •Innovation.
PDCA / company goal & company. external.
DMAIC. as priority.

2013-2018
Competition Winner Category
1st Winner
2nd Winner
3rd Winner
TRAINING

TRAINING JURY:
Jury for IFI: level M1 up
Jury for GKM: Level M2 up

Training Jury (level assistant manager up) to build same perception between Jury
PHASE 3

3. Insert Kaizen activity as a KPI in every department

KPI Factory PT Amerta Indah Otsuka 2018

PHASE 3

Problem:
• Down trend proposal Improvement

Action:
1. Insert additional specific facilitator to support & Periodically
Gathering
 PHASE 4
2020-2024
Change & External
Benefit
PHASE 4

Benchmark to ‘The Best in Class’ Company

Problem:
Integration system between machine, human and network
communication in advance level
Action:

Transformation Industry 4.0 (internet of think)

Benchmark Learning Institut Benchmark for Smart Factory 4.0

GREETING INTRODUCTION THEME

Purpose : Statement of Mind to build Kaizen Spirit for each employee.

Issue every Kaizen activity such as weekly morning meeting and convention.

Passion For
Salam Improvement!
Improvement!
Salam
Improvement! Go Improvement!

2016 - 2018
2019 - Current
CIRCLE ACTIVITIES
INTERNAL CONVENTION

CONVENTION follows circle

periods,
Normally two Batch/year
EXTERNAL CONVENTION

TEMU KARYA MUTU & PRODUKTIVITAS NASIONAL (TKMPN XXII)

 Team AIO SUKABUMI (DARAH MUDA) → PLATINUM

 Team AIO SUKABUMI (ENERGIZE) → PLATINUM
 Team AIO KEJAYAN (RESPECT) → GOLD
 INTERNAL RESULT QUANTITY ACHIEVEMENT IFI
Achievement IFI

5.5
3500 5.7
4.7 4.7
3000 4.7
3118
2500
2668 2665 3.7
2000

Idea/ MP
Qty

2.7
1500
1.7
1000
0.5 0.4
500 226 0.7
265
0 -0.3
2014 2015 2016 2017 2018

Qty Idea Idea/MP

INTERNAL RESULT QUANTITY ACHIEVEMENT ATCI

ACHIEVEMENT OF ATCI FOCUS BENEFIT PROJECT THEME 2018

Cost
600
3
480 493 11%
500
Energy
3
400 11% Line
298 Efficiency
MP

300 11
41%
200

100 65 65
43 Rejection
51 46 10
0 27 37%
2016 2017 2018

Employee Contribution Project Plan Project Complete

FINANCIAL BENEFIT

Financial Benefit from Project Improvement

Rp12
Billions

Rp10

Rp8

Rp6

Rp4

Rp2

Rp-
2017 2018

Saving Potential Saving

 PASSION
TO CREATE THE FUTURE
WITH LOVE