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PT PERFETTI VAN MELLE INDONESIA

Candradimuka Excellent Center


9 October 2009

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SHOPFLOOR BEST PRACTICES

Shop Floor Best Pratices

Activities:
1.5S Program
Objective:
2.Group Leader Enhanchement
3.Shop Floor Meeting
4.Q-Sign
5.Control Critical to Quality (CTQ)
SHOPFLOOR BEST PRACTICES

A '5S' is a system which driven enhances productivity and


competitiveness and fosters a productivity culture through
workplace organization and a continual process of identifying,
reducing and eliminating MUDA (Japanese for Waste).

5 S as a fundamental to all continuous improvement activities.


Objective of 5S are:
•Identify, Reduce and Eliminate MUDA (waste)
•Organize & establish a World Class workplace
•Enhance Productivity & Competitiveness
•Improve work life

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SHOPFLOOR BEST PRACTICES
5S Program
5S stands for:

1. Seiri / Sort
    Clearly distinguish necessary items from unnecessary
items and eliminate the unnecessary.
2. Seiton/Shine
    The regimented, scheduled, standardized cleaning of the
work area.
3. Seiso/Set in order
    Keep only necessary items in the correct place for quick and
easy retrieval.
4. Seiketsu/Standardize
    Tools used to maintain the first three S’s.
5. Sitshuke/Sustain
    Sustaining is performing and improving the 5S’s on an ongoing
and regular basis.

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SHOPFLOOR BEST PRACTICES
5S Program

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SHOPFLOOR BEST PRACTICES
5S Program

2007 2008 2009

a. Impleme
nt Short
b. Impleme
nt Set in
order
c. Impleme
nt Shine

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SHOPFLOOR BEST PRACTICES
5S Program
Sustain
Standardize

Pilar
Pilar  Pilar 
Set in 
Short Shine
Order

Awwareness of All Employees
Commitment of Management
4 steps to implement 5S program:
1.Commitment of Management
2.Awwareness of all employies
3.Implement 5S Program
4.Evaluation 5S Proram by Competition 5S

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SHOPFLOOR BEST PRACTICES
5S Program

Management conduct the Lean Manufacturing Program and 5S


Program was be developed and maintananced by it.
This is a example of contract sheet in LMP ;

5S Program

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SHOPFLOOR BEST PRACTICES
5S Program
To keep continuing 5S campaign to all employies by 5S Training;
Opening Refreshment 5S by Pak Isack

Rule of The Competition by Anang YR Participants, serious but relaxed

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SHOPFLOOR BEST PRACTICES
5S Program
Training-Audit sesion

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SHOPFLOOR BEST PRACTICES
5S Program

Rule of the Competition :


1. The Auditor Team will give the score Every Audit.

2. The Auditor Team will choose the Winner and the Looser every
month base on the score

3. The Winner Area will receive the Gold Flag and the Looser Area
will receive the skull flag

4. The score will be accumulated and on the end of competition will


be decided who the WINNER is.

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SHOPFLOOR BEST PRACTICES
5S Program 5S Recognition Board:
Area name

Period of audit

The Badge for score


under the standard

The Badge for score


in the standard

The Badge for score


above the standard

The Banner for


highest score
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SHOPFLOOR BEST PRACTICES
5S Program
5S Recognition Board:

The Banner for


lowest score

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SHOPFLOOR BEST PRACTICES
5S Program
Develope and upgrade the checklist
For 5S Audit

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SHOPFLOOR BEST PRACTICES
5S Program
•Inauguration of 5S Auditor (Confirmation as 5-S auditor in CBN)

Dengan ini kami mengangkat Tim


Auditor 5-S yang berkomitment untuk
mensukseskan Program 5-S di
PT.Perfetti Van Melle Indonesia

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SHOPFLOOR BEST PRACTICES
5S Program
•Inauguration of 5S Auditor (Confirmation as 5-S auditor in CKP)

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5S Program
•Coaching 5S Auditor by Plant Director

Indoor Outdoor

Outdoor

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SHOPFLOOR BEST PRACTICES
5S Program
•Up grade 5-S audit standard (socialization new checklist at CKP )

Socialization to CKP-area owner by 5-S Coordinator , May 29, 2009


on Srikandi Room

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SHOPFLOOR BEST PRACTICES
Devide Plant Cibinong and Cikampek to some area 5S

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SHOPFLOOR BEST PRACTICES
5S Program

Foto audit oleh auditor

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SHOPFLOOR BEST PRACTICES
5S Program
•Result Audit 5S Period September 2009 Cibinong

Production Supporting Production


Cross Functional Team, Make more and more, better and better
LMP III, 2009 Page 21 with less and less…
SHOPFLOOR BEST PRACTICES
5S Program
•Result Audit 5S Period September 2009 Cikampek

Production Supporting Production

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SHOPFLOOR BEST PRACTICES
5S Program
Monthly Recognition Event

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SHOPFLOOR BEST PRACTICES
5S Program
Yearly Recognition Event
For 5S WINNER

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SHOPFLOOR BEST PRACTICES

4 Activities:

a.Selection The Group Leader


b.Comprehensive Training
c.Review Group Leader Performance
d.Shop Floor Management Coaching

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SHOPFLOOR BEST PRACTICES
a. Selection The Group Leader
Review Organization Structure
a.Selection The Group Leader

Interview and Selection

All candidates will be tested and interviewed about;


a.Process knowledge and know how
b.Knowledge of equipment, machine, skill, extr
c.Decipline
d.Moral improvement
e.Compliance culture
f.Leadership
g.Self Confidence
h.Human relationship
i.Problem solving

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SHOPFLOOR BEST PRACTICES
b. Comprehensive Training

Develop Group Leader Training Module


Focus Program :
a. Process and Production Knowledge
b. People Development
c. Learning Organization
d. Cost Overview
e. Quality Overview

Focus Program divided into 38 training modules


SHOPFLOOR BEST PRACTICES
b. Comprehensive Training

38 Training Modules
Make more and

Phase 1 : Floor Supervision more, better and


better…with less
and less !

b. Comprehensive Training

Training Execution :
• Executed May – Aug 2007
• Coverage all training modules
• Training delivered by competent internal resources
• At the end of every training completed by a test
• All Group Leaders should pass all tests
• Finished by Group Leader graduation
Make more and

Phase 1 : Floor Supervision more, better and


better…with less
and less !

b. Comprehensive Training Training Execution


Training Opening Hygine Training

5S Training

Spirit of ice breaking


Phase 1 : Floor Supervision

b. Comprehensive Training
Thinking Out of the Box
Make more and
Phase 1 : Floor Supervision
SHOPFLOOR BEST PRACTICES more, better and
better…with less
and less !

b. Comprehensive Training

Q & A Session

Training Execution – Closing & Graduation


SHOPFLOOR BEST PRACTICES
 b. Comprehensive Training

Fantastic Games

Training Execution – Closing & Graduation


SHOPFLOOR BEST PRACTICES
 b. Comprehensive Training

Self Reflection

Training Execution – Closing & Graduation


SHOPFLOOR BEST PRACTICES
 b. Comprehensive Training

Graduation

Training Execution – Closing & Graduation


SHOPFLOOR BEST PRACTICES
 b. Comprehensive Training

Strategies : 3. Training Execution – Closing & Graduation

Graduation
SHOPFLOOR BEST PRACTICES
c. Review Group Leader Performance

Review Group Leader #2, August 20, 2009 on Krakatau Room

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SHOPFLOOR BEST PRACTICES
 d. Shop Floor Management Coaching (SFMC)
SFCM is a coaching for Group Leader of the area by Plant Manger
and Production Manager and followed up by a touring on the floor to
review several issues: safety, schedule, quality, leaderships and
others
The coaching methods :
• In the room : for approximately 5 minutes
• On shop floor : for approximately 25 minutes

This coaching monitored by using “Progress Report Form” and in the


year end period will be reviewed and used to support annual
appraisal for Group Leaders

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 d. Shop Floor Management Coaching (SFMC)

The Schedule of coahing


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SHOPFLOOR BEST PRACTICES
 d. Shop Floor Management Coaching (SFMC)

The Progress report form


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SHOPFLOOR BEST PRACTICES
 d. Shop Floor Management Coaching (SFMC)
Progress Report Form for
Coaching

minimum achievement score must be 7

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0
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4
6
8
10
12
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10 10 10 10 10

Sy won
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Fi ka
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 d. Shop Floor Management Coaching (SFMC)

Jo
ko
8

Iw
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8
Achievement Score for Group Leader Coaching

Um
a
8

Na r 
sa
Sl ri
am
10

et
8

Ru
di
Ya
10

z id
7

Pu
SHOPFLOOR BEST PRACTICES

dj
i
8
SHOPFLOOR BEST PRACTICES
 d. Shop Floor Management Coaching (SFMC)

Cibinong Cikampek
4 Group Leaders 2 Group Leaders

REWARDS :
Best Group Leader based on coaching achievement score per
line will be recommended as team building relevant invited
participants next year

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SHOPFLOOR BEST PRACTICES

SFM is a meeting within Group Leaders and Operators


Executed in a standing meeting format on the floor at the
beginning of the shift
The main topic discussed : safety, schedule, quality and other
related issues
Objectives ;
i. Streamlining communication and direction
ii. As communication pipe for all company programs
iii. Quick responds and up date from operators
iv. Improve level of urgency
v. Easier to deliver production brief/issues

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SHOPFLOOR BEST PRACTICES

SFM

SFM

Lay Out shop floor meeting area


SHOPFLOOR BEST PRACTICES

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SHOPFLOOR BEST PRACTICES

Guest speaker from engineering Guest speaker from NPD Guest speaker from Production

Guest speaker from engineering Guest speaker from SHE Guest speaker from QC

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SHOPFLOOR BEST PRACTICES

Cibinong Cikampek
G r a f ik  K e h a d ir a n  S h o p  F lo o r  M e e t in g G r a f ik  K e h a d ir a n  S h o p  F lo o r  M e e t in g

1 0 0 .0 % 1 0 0 .0 %
9 0 .0 % 9 0 .0 %
8 0 .0 % 8 0 .0 %
7 0 .0 % 7 0 .0 %
6 0 .0 % 8 9 .5 % 6 0 .0 %
9 6 .0 % 9 3 .0 % 9 6 .5 % 9 4 .5 % 9 7 .4 % 9 7 .4 % 9 4 .5 %
5 0 .0 % H a d ir 5 0 .0 % H a d ir
4 0 .0 % 4 0 .0 %
Ab se n Ab se n
3 0 .0 % 3 0 .0 %
2 0 .0 % 2 0 .0 %
1 0 .0 % 1 0 .5 % 1 0 .0 %
4 .0 % 7 .0 % 3 .5 % 5 .5 % 2 .6 % 2 .6 % 5 .5 %
0 .0 % 0 .0 %
D r a g e eP a c k i n gC h e w y A l p e n A B C D
G ro u p G ro u p

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SHOPFLOOR BEST PRACTICES

Q-Sign is a quality sign which be installed at the critical area


which all employees should be awware to the quality
of product.
It consist the sign and one point lesson (direction) for operator
to control the isue of product defect.

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SHOPFLOOR BEST PRACTICES

•Implement widely Q-sign with ‘one point lesson’ structure

Q-sign picture

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SHOPFLOOR BEST PRACTICES

Compliance of Cleaning Filter, Magnetic Trap and Metal Detector


Filter Magnetic Trap Metal Detector

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SHOPFLOOR BEST PRACTICES

Compliance of Cleaning Filter

Cibinong Cikampek

100% 100% 91%


100% 100%
100% 89%
Data compliance
80% 73%
cleaning filter 100%
80%
Dragee
80% 100.0% 75%
80%
Alpenliebe
60% 100.4%
Chewy
40%
91.2% 60%

Average 97.2% 40%


20%
20%
0%
N o ve m b e r Desem ber
0%
D ra g e e   A lp e n lie b e Chew y N o ve m b e r D esem ber

C o a te d F o rm in g

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SHOPFLOOR BEST PRACTICES

Compliance of Cleaning Magnetic Trap

Cibinong Cikampek

100%100% 1 0 0 %1 0 0 % 1 0 0 %1 0 0 %
100% 100% 100% 100% 100% 100%
Data com pliance celaning m agnetic trap
100%
100%
80%
Dragee 100.0% 80%
60%
Alpenliebe 100% 60%
Average
40%
100.0% 40%
20%
20%
0%
O ld  S D N e w  S D A lp e n lie b e 0%
Babol C h e w y c o a te d G o lia fo rm in g
No ve m be r D e se m b e r
N o ve m b e r Desem ber

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SHOPFLOOR BEST PRACTICES

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SHOPFLOOR BEST PRACTICES

Compliance of Cleaning Metal Detector

Cibinong Cikampek

100% 9 0% 92 %
Data com pliance
90% 9 0%
m9 etal
0 % 90 %
detector 100%
100% 100% 100% 100% 100% 100%

80%
Dragee 91.9% 80%
60%
Alpenliebe 90.0% 60%
40%
Chewy 90.0% 40%
20%
Average 90.6% 20%
0%
Dr a ge e   Alpe nlie be C he w y
0%
Babol C h e w y c o a te d G o lia fo rm in g
N o ve m b e r D e se m b e r

N o ve m b e r D es em ber

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SHOPFLOOR BEST PRACTICES

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