#2 Report of Supermarket Improvement Team

MKM Engine Plant

19 April 2016
Martinus T.S

PPC Engine Plant PT MITSUBISHI KRAMA YUDHA MOTORS AND MANUFACTURING Internal
MKM-FORM-01/2013
 (REMINDER)

1st Improvement: Trial Belanja = 1

Old Condition
operator
Balancing Work Process Cycle time unpacking & belanja

4.50 4.50

4.00 4.12 4.00 New Job

Target C/Time= 2.83 C/Time will be Tried
3.50 Target C/Time= 2.83 3.50

3.00 3.00
Minute

Minute
2.88
2.50 2.77 2.50 2.77 2.88

2.42
2.00 2.00

1.50 1.50

1.00 1.00
1.05
0.50
0.50
0.00
0.00
Edy-san Arip-san Agus-san Jaja-san
Edy-san Arip-san Agus-san (RH) Jaja-san (LH)
(RH/LH)
: C/T Unpacking
C/T Unpacking :C/T Belanja
C/T Belanja :C/TTarget
Setting :C/T Target
C/T Supermarket : C/T Unpacking
C/T Unpacking :C/T Belanja
C/T Belanja :C/TTarget
Setting :C/T Target
C/T Supermarket

Note: Revise Target Cycle Time Supermarket

Old : 2.17 (Base on Max Composition)
New : 2.83 (Base on SASS Volume)

PPC Engine Plant MKM-FORM-02/2013 P- 2

 CONTENT

1. Schedule Improve Step-1 : Improvement Belanja

2. Evaluation 1st Improvement : Trial Belanja = 1 Operator

3. 2nd Improvement : Trial Change Manpower & Re-Training

4. Improve Step-2 : Change Flow Process Supply (Front Line)

5. Schedule Improve Step-2 : Improvement Process Supply

PPC Engine Plant MKM-FORM-02/2013 P-3

 SCHEDULE IMPROVE STEP-1: IMPROVEMENT BELANJA
PROGRESS JAN FEB MAR APR
NO COUNTERMESAURE REMARK
25% 50% 75% 100% I II III IV I II III IV I II III IV I II III IV
P
1 Moving Rack Position
A
P
2 Daisha Modification
A
P
3 Additional Photo Part
A
P
4 Training to Operator
A
P
5 Instal Fan
A
P
6 Supermarket Audit at Assy Line-2
A
Socialization to operator unpacking: Open P
7
the packaging when input part to rack A
P
8 Create Polybox Partition
A
P
9 St udy & Simulation Flow Process Belanja
A
P
10 Report the Result of Simulation
A
P
11 Create Attachment Part
A
1st Improvement: Trial Operator Belanja = 1 P
12
Orang & Evaluation A
nd
2 Improvement: Trial Change Manpower P
13
& Re-Training & Evaluation A
P Target
14 Go Live
A C/Time = 2.78 Achiev

PPC Engine Plant MKM-FORM-02/2013 P-4

 2. EVALUATION 1st IMPROVEMENT: TRIAL BELANJA = 1 OPERATOR

Operator Belanja Operator Belanja

LEGENDS:
ARIP EDY
: Daisha Transfer
AGUS JAJA
: Daisha Standard

: Route of Op. Belanja

RH RH LH LH

IN OUT
IN OUT
W/M W/M CB
W/M CS
CH

PPC Engine Plant MKM-FORM-02/2013 P-5

 OLD CONDITION TRIAL OPERATOR BELANJA= 1 OPERATOR

JAJA
Operator Belanja Operator Belanja Operator Belanja Operator Setting
ARIP EDY ARIP EDY

AGUS JAJA
AGUS

RH RH LH LH RH RH LH LH

OUT OUT
IN IN

Input part to Rack not yet setting condition Input part to Rack has been Setting condition per 6 unit by
Operator Setting

PPC Engine Plant MKM-FORM-02/2013 P-6

 Cycle Time
Cycle time of Trial Operator Belanja = 1 Operator DESCRIPTONS
(Menit/Unit)

BEFORE 4.12

AFTER 4.6
SUPERMARKET
4.50 4.60 ASSY LINE-2 TARGET 2.83

4.00 4.12 STATUS R

3.50
Minute

3.00 Target C/Time = 2.83

2.88
2.50 2.77
2.42
2.00

1.50

1.00
1.05
0.50

0.00
Edy-san Arip-san Agus-san Jaja-san
(RH/LH)
: C/T Unpacking :C/T Belanja :C/T Setting

PPC Engine Plant MKM-FORM-02/2013 P-7

 3. 2nd IMPROVEMENT: TRIAL CHANGE MANPOWER &
RE-TRAINING
Cycle Time
DESCRIPTONS
(Menit/Unit)

BEFORE 4.12 Change Posistion

AFTER 2.78
SUPERMARKET
ASSY LINE-2 TARGET 2.83 Balancing
STATUS G

Cycle Time
JOB DESC. DESCRIPTION (Old)
LEGENDS:
ARIP EDY
: Daisha Transfer
Rack, Kitting Part, &
Arip-San 2.88
2.58 #2 AGUS JAJA
Setting 8 Item Small Part : Daisha Standard
UNPACKING
Washing Machine & : Route of Op. Belanja
Edy-San 2.77
Kitting Part

Rack RH Agus-San
Jaja-San 4.12
2.78
RH RH LH LH
BELANJA #1
Rack LH & Setting 8 Item
Rack Agus-San 2.45
SmallLH
Part Jaja-San 2.42
2.74

IN OUT
IN OUT
W/M W/M CB
W/M CS
CH

PPC Engine Plant MKM-FORM-02/2013 P-8

 4.5

4 4.12

3.5
Target C/Time = 2.83
3
2.88
Menit / Unit

2.77 2.77 2.78 2.74

2.5
2.58
2.42
2

1.5 B B B B
E A E A E A E A
1 F F F F F F F F
O T O T O T O T
0.5 R E R E R E R E
E R E R E R E R
0
Arip-San Edy-San Agus-San Jaja-San

Cycle Time Unpacking Cycle Time Belanja

BEFORE AFTER
REMARK
Cycle Time Cycle Time
JOB DESC. DESCRIPTION (Old) JOB DESC. DESCRIPTION (New)

Rack, Kitting Part, &

Arip-San 2.88 Rack & Kitting Part Arip-San 2.58 Balancing
Setting 8 Item Small Part
UNPACKING UNPACKING
Washing Machine & Washing Machine &
Edy-San 2.77 Edy-San 2.77 No-Change
Kitting Part Kitting Part

Rack LH & Setting 3 Item Reposition &

Rack RH Agus-San 4.12 Agus-San 2.78
Small Part Balancing
BELANJA BELANJA
Rack LH Jaja-San 2.42 Rack RH Jaja-San 2.74 Reposition

PPC Engine Plant MKM-FORM-02/2013 P- 9

 4. IMPROVE STEP-2: CHANGE FLOW PROCESS SUPPLY
(FRONT LINE)
4.1 CURRENT CONDITION

FRONT LINE KANAN (RH) READY SUPPLY PREPARATION RH

FRONT LINE KIRI (LH) READY SUPPLY PREPARATION LH

Prod. Engine Dept. P - 10

MKM-FORM-02/2011
4.2 CURRENT SUPPLY
DAISHA SUPERMARKET F/L KIRI (LH)

QTY Supply /
12 unit

QTY Supply /
12 unit

BOX KITTING F/L

QTY Supply /
1 unit DAISHA SUPERMARKET F/L KANAN (RH)
P - 11
Prod. Engine Dept. MKM-FORM-02/2011
4.3 IDEA IMPROVEMENT

DAISHA SUPERMARKET F/L KIRI (LH) DAISHA SUPERMARKET F/L KANAN (RH) BOX KITTING F/L

BOX F/L KITTING & SUPERMARKET

P - 12
Prod. Engine Dept. MKM-FORM-02/2011
4.4 IMPROVEMENT SUPPLY

Part Supply Condition

Part Condition in Line Side

P - 13
Prod. Engine Dept. MKM-FORM-02/2011
4.5 CYCLE PROCESS SUPPLY at FRONT LINE

Legends

: Daisha Transfer

: Daisha Standard
2 QTY Belanja / 1 unit 1 QTY Belanja / 1 unit
1
~ 5 : Big Part
1 1
5 : Polybox Khusus
2 2

: Route Battery Car 3 3

4 4
: Route Op. Belanja
5 5

5 5

Daisha Transfer + 88% Part in Box Daisha Transfer + Empty Box

Daisha Transfer + 100% Part in Box Daisha Transfer
0

IN OUT

W/M W/M CB
W/M CS
CH

MERIT DEMERIT
1. Reduce 1 Manpower PPC 1. Additional Daisha Transfer (2 unit)
2. Additional Polybox & Attachment (10 pcs)
PPC Engine Plant MKM-FORM-02/2013 P- 14
4.5 DETAIL “BELANJA” ACTIVITY

Cycle Time
DESCRIPTONS
(Menit/Unit)
BEFORE 2.78
AFTER 2.817
SUPERMARKET
TARGET 2.83
ASSY LINE-2
STATUS G

PPC Engine Plant MKM-FORM-02/2013 P- 15

 5. SCHEDULE IMPROVE STEP-2: IMPROVEMENT PROCESS SUPPLY
APRIL'16 MAY'16
NO DESCRIPTIONS PIC
I II III IV I II III IV
1 Coordination Meeting Team 12
2 Pembuatan Attachment Part (10 Pcs) Joko
3 Trial New Concept Supply Joko/Edy 16
4 Report Hasil Trial Ardian 18
5 Pembuatan Attachment Part (50 Pcs) Joko
6 Request Penambahan Daisha (2 Unit) Adi ETA

7 Pembuatan Shutter Baru Joko/Adi

8 Modifikasi Daisha (Dipendekkan) Joko
9 Request Penambahan Polybox & Material Attachment (10 Pcs) Adi ETA

10 Pembuatan Attachment Polybox (10 Pcs) Joko/Adi

11 Go Live Team 16

PPC Engine Plant MKM-FORM-02/2013 P- 16

 Arigatou
Terima kasih
 BACKUP DATA

PPC Engine Plant MKM-FORM-02/2013

 BASE DAISHA STANDARD
Current Condition (investigation)
Almost all daisha conditions are the same:
There are 3 pieces:
Mapping sheet CJM Model
Mapping sheet SLD Model
Base sheet

there are small edges and

boxes seemed

Daisha Supply Supermarket

Improvement Condition

2cm

measurement of height of the measurement of thick "sheet began today, all of daisha use only "1
"base" to "edges" = 2,30cm mapping" = 0.30 cm mapping sheet" which is at once as a
"base sheet"

PPC Engine Plant MKM-FORM-02/2013

 SCHEDULE PIN LOCK DAISHA
APRIL 2016 MAY 2016
NO DESC TOTAL
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8

1 Working Hour 7 7 7 7 7

ETA
1 Order Material By PE

2 Planning (71 Daisha) 14 14 14 14 15 71

3 Actual 14 14 28

BEFORE AFTER
PPC Engine Plant MKM-FORM-02/2013
PPC Engine Plant MKM-FORM-02/2013
 SCHEDULE STOPPER DAISHA

APRIL 2016 MAY 2016 JUN 2016

NO DESC TOTAL
20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5

1 Order Material By PE 167pcs ETA

2 Planning (167 Daisha) 14 4 4 4 14 4 4 4 4 4 14 4 4 4 4 4 14 4 4 4 4 4 14 4 4 4 13 167

3 Actual 0

NOTE : PRICE STOPPER PER PCS = ±Rp. 900.000

TOTAL COST (167 unit) = Rp. 150.300.000

TRIAL STOPPER 1 unit

PPC Engine Plant MKM-FORM-02/2013

PPC Engine Plant MKM-FORM-02/2013
 CYCLE TIME NEW BATTERY CAR

Manual Handling Battery Car Handling

NO LINE DESCRIPTION
Jumlah Jumlah Jumlah
C/Time C/Time
Operator Operator B/Car
Daisha Transfer Kitting-Front Line 3.5 1 1.84
1 Assy Line-2 1 1
Daisha Transfer Crankshaft 3.35 1 2.1

Daisha Transfer Kitting-Front Line 2.26 1 1.47

2 Assy Line-1 1 1
Daisha Transfer Kitting-Main Line 3.34 1 1.8

TOTAL 4 2 2
NOTE: REDUCE --> MANPOWER ASSY LINE-1 = 1
MANPOWER ASSY LINE-2 = 1

PPC Engine Plant MKM-FORM-02/2013

 MASTER SCHEDULE

2016
No. Description
Feb Mar Apr May Jun Jul

1 STEP-1: ASSY LINE-2

1.1. Genba Audit

1.2. Analysis & Countermeasure

1.3. Action Plan

1.4. Evaluation

1.5. Summary

2 STEP-2: ASSY LINE-1

2.1. Genba Audit

2.2. Analysis & Countermeasure

2.3. Action Plan

2.4. Evaluation

2.5. Summary

3 STEP-3: ASSY LINE-TM

3.1. Genba Audit

3.2. Analysis & Countermeasure

3.3. Action Plan

3.4. Evaluation

3.5. Summary

PPC Engine Plant MKM-FORM-02/2013

 BALANCING PROCESS: SETTING 8 ITEMS SMALL PARTS

Small Part I/Pump Steam Seal Director

PPC Engine Plant MKM-FORM-02/2013