Participant Name: Albertus Bagus Irawan

Company: TMMIN
Function:
Vehicle Production Karawang 2
Warih A.T. J

Prework for MDP Individual Project THEME SELECTION CRITERIA

Purpose: To identify the highest priority issue that should be addressed by each MDP participant for their company to be successful in the (a) Select a problem from your own division or function that has a company
future (b) The problem should be connected to a key hoshin initiative in the comin
(c) The problem solution may have some yokoten opportunity in the region

1. WORKPLACE MISSION 4. WORKPLACE VISION

For what reason does your workplace exist and what value does it provide? Within the next 3-5 years, to what level would you like to improve the value

Workplace Mission Element Additional Explanation Your Answer Workplace Vision Element Additional Explanation
(i) For whom does your workplace exist? Who is the customer of your workplace? Toyota car's marketing and dealer. End customer is Toyota (i) What, by when, to what level or From your customer's pe
Car's user. conditions? improve, and by how mu
(iii) What is the purpose of your workplace? Why does your workplace exist? To provide passenger car with good quality and competitive
cost for both domestic and global customer.
(iii) What type of workplace is From your own perspect
required (workplace conditions)? conditions in the workpla
(iii) What products/services does your What do you do? We produce passenger cars (4 models) starting from welding achieve (i) above?
workplace provide? process until assembly process.

To Be The Best Car Manufacturer in AP Region and contribute to Company and Toyota Indonesia’s business To be the most efficient and produ
Your Workplace Mission: Your Workplace Vision: Production Target in 2018.
competitiveness by producing best passenger car for domestic and global customer.

2. WORKPLACE ENVIRONMENT How will your Workplace Vision contribute to your compan
What environmental changes are occurring which could impact your workplace? - We will able to produce passenger cars with high product
External Environment - Level Up existing models by enhance cost competitivenes
Internal Environment
Global Domestic
a. Global Market Outlook (All Brand) a. Indonesia Domestic Market a. TMMIN Production Volume x1,000 units
(x/1000 u/year )
Toyota Market TMMIN Prod 5. WORKPLACE KPIs
2015 2016f 2017f 2018f 1,145K 376
10,000
1,060K 1,100K 343 361 What issues have continued from the previous year and remain unresolved
1,031K 325
8,000 275 290
6,000 191 216 Issue/KPI Result
4,000 14 %
SQA DpU
-2 % 1% -13 %
2,000
31,6% 32,4%
32,9% 32,9% - Shipping Qua
- target but nee
As i a Ea st As i a Mi d. Ea st Afri ca 2015 2016f 2017f 2018f
Source : 2016 RAP - TMAP EM + N.Afri ca 2015 2016f 2017f 2018f TMMIN production condition tend positive & gradually increase BMC

Automotive Market is tend stagnant but Asia region - Indonesia market forecast recover from 2015
market Growth 14% - Toyota market share stable from 31.6% until 32.9% b. TMMIN Competitiveness

b. Future Business Challenge in Asia b. Indonesia Market Competitors Shipping Quality Audit DpU need to
improve

- Man Power e
to improve.

Have to sustain the profit. file:///conversion/tmp/scratch/456995402.xlsx

 c. TMMIN Have to sustain the profit.
Profit
PEFF Achievement still below target

1. CAFE has been introduced in some countries

2. NCAP actifities and safety regulation changes Other competitor 's market share tend to increase.
Challenge : How to survive current model with Aggressive 6. IDENTIFY CRITICAL ISSUES IN YOUR WORKPLACE
3. CH, KR, IN-made vehicles lower tariff import
competitors Considering the outputs (shaded boxes) of 1, 2, 3, 4 and 5, what do you th
Big Impact to the Competition We still on the way to increase and level-up the competitiveness.
Product/Service Provided by
Current Achievement Lev
Your Workplace
3. COMPANY HOSHIN (OR MID-LONG TERM BUSINESS PLAN) 1. Quality Achievement (SQA) nee
What issues stated in your company's Hoshin (or mid-long term business plan) connect to your workplace? Passenger cars with
Company Vision : good quality and
To be the best, most Flexible Toyota Company in Asia Pacipic & most Admired Company in Indonesia as Basis to strengthen Indonesia Automotive Industry competitive cost 2. Man Power Efficiency still low

Objective :
Build and Re-shape TMMIN's Competitiveness to Face Future Business Challenge.

7. MDP THEME SELECTION

Using (6), consider which issue you should select for your MDP theme and explain the reason for your selection.

MDP Theme How will your Theme contribute to your Company in the Mid-Long Term?

Increase TMMIN's Productivity Competitiveness through Creating PEFF Management Culture, by Leader Support TMMIN to Secure 300K Production Volume
Development, Accelerating Unique Kaizen Activities and Improve Working Environment & Expand Business

file:///conversion/tmp/scratch/456995402.xlsx
 J. Nandi Julyanto A. Bagus Irawan

(a) Select a problem from your own division or function that has a company wide impact.
(b) The problem should be connected to a key hoshin initiative in the coming year which links to achievement of your long term vision.
(c) The problem solution may have some yokoten opportunity in the region. (you may consider choosing a theme that is common across the region).

Within the next 3-5 years, to what level would you like to improve the value of the products/services that your workplace provides?

Additional Explanation Your Answer

From your customer's perspective - what should you Can improve cost competitiveness (achieve CIM <1.0 )
improve, and by how much? in 2018.

From your own perspective, are there any methods or Need to improve In-house KPI, focusing on quality and
conditions in the workplace that need to be improved to productivity.
achieve (i) above?

To be the most efficient and productive Car Manufacturing in AP Region by Achieving best KPI to secure 300K
Production Target in 2018.

How will your Workplace Vision contribute to your company's Hoshin (or Mid-Long Term Business Plan)?
- We will able to produce passenger cars with high productivity and competitive cost as a strong foundation towards Global Level Operation & TNGA
- Level Up existing models by enhance cost competitiveness to secure 300K & expand business

What issues have continued from the previous year and remain unresolved? What KPI's were not achieved?
Reason Potential Countermeasure

- Shipping Quality Audit Result achive the - Improve workplace genba and collaborate with related
target but need to improve to compete with parties as one team for Quality Improvement.

- Man Power efficiency (MPEFF) still need - Man Power Development by TPS Key Person,
to improve. GL Level Development and accelerate TPS Activity

- Gentan-I review and reduce

file:///conversion/tmp/scratch/456995402.xlsx
 - TMMIN Unique Kaizen and Jishuken Activity

6. IDENTIFY CRITICAL ISSUES IN YOUR WORKPLACE

Considering the outputs (shaded boxes) of 1, 2, 3, 4 and 5, what do you think are the critical issues to be resolved in your workplace?
Considerations (Resources,
Current Achievement Level Ideal Achievement Level
Required Information, etc)
1. Quality Achievement (SQA) need to improve 1. Compete with BMC as a minimum target - Quality Improvement
and review all STW
(Back to Basic Activity)
2. Man Power Efficiency still low 2. PEFF > 1 - Cycle time comparing
with "kijyun jikan"
- Supporting from related
Division

Who are the Stakeholders you will need to Consult or Obtain Support from?

OMDD, Finance, Purchasing, Production Control, Plant Administration,

TMC Motomachi, TMAP-EM

file:///conversion/tmp/scratch/456995402.xlsx
 2015 2016f 2017f 2018f
Toyota Market 325 343 361 376
TMMIN Prod 191 216 275 290 Future
Business
Environment

Data #1 . Market Assumption by Area (Global)

Asia East Asia Mid. East Africa
2013 6,982 3,200 2,800 1,800
2014 6,634 3,200 2,600 1,700 Impact
to
2015 7,166 3,300 2,700 1,800
Toyota
2016 7,556 3,300 2,800 1,800

Data #1 . Market Assumption by Area (Global)

Mid. East
Asia East Asia + N.Africa Africa
2015 6,995 3,582 3,821 822
2016f 7,048 3,526 3,327 709
2017f 7,048 3,516 3,617 704
2018f 7,962 3,512 3,852 718
Competitiveness
Item

Safety

[Accident]
14% -2% 1% -13%

Quality

[SQA dpu]

Productivity

[PEFF - KJ]
 Policy Change
Future Growth Customer
Business of Preference Fuel Safety Expansion of
Environment Market Change Efficiency Regulation FTAs

Increase Higher PC Sales (Low profitability) Increase Increase

Sales Lower IMV Sales (High profitability) Vehicle Cost Competition

Impact
to
Toyota IMV
Toyota operating
profit may reduce
even if sales increase Small
PC

Current Future Current Future

-- Sales Vol. -- --- Profit ---

Competitiveness BMC
Target TMMIN Evaluation
Item (Best Achieve)

Safety
0 0 0 [Lower is Better]
[Accident]

Quality
0.2 0.2 0 [Lower is Better]
[SQA dpu]

Productivity
1 0.69 0.66 [Higher is Better]
[PEFF - KJ]