JISHUKEN AHM

ENGINEERING DEPARTMENT
Problem Statement & Improvement Goal

① ② ③ ⑩

⑤ ⑧ ⑨

Core Process : Produksi & Quality [Green

Zone ; Yellow Zone ; Red Zone]

Improvement
dilakukan pada
④ ⑥ ⑦ ⑪
Pembuatan Produk
Baru
 Problem Statement & Improvement Goal

PROBLEM STATEMENT PERFOMANCE EVALUATION [KPI]

• Event PP2 Go dan Mass Pro Achievement category

Re-Look project management performance excellent setiap event
mendapatkan penilaian x ≤ 50 System base on Prosedur New
[Poor] new project
Project 90 < x ≤ 100 [Very Good]

IMPROVEMENT
JUDGEMENT SCORE FINAL SCORE
VERY GOOD 90 < x ≤ 100
GOAL
GOOD 75 ≤ x ≤ 90
FAIR 50 < x < 75 Improve Project
POOR x ≤ 50 Management
90 < x ≤ 100 [Very Good]
Event D
100

Event D
100

Event Mass 100

P 100Event E-1
75
25 90
0
DPP Perfomance Event Mass 100
P 90 100
Event E-1
AHM Score 90
DPP Perfomance 75
42 25
AHM Score 0
58
TARGET 90

100 100
Event QAN Event PP2-GO 58
42
90 90
Event PP2 Go dan Mass Pro mendapatkan penilaian di bawah
standar minimal penilaian Part Development. 100
Event QAN
100
Event PP2-GO
 Background

Flow Project New Model Concern Item

Fase draft costing Fase propose Fase Final maker Layout Fase Trial Assy Unit & Fase Evaluation Mass
& Perspektif maker maker layout & & Cost evaluation (All Evaluation test Prod
layout cost evaluation Die Go ) (Hinanhyo)

Performance Evaluation

Voice Of Customer Concern

Item
PD Event  MP Fase Planing Fase Trial & PP Fase Mass prod
( C  G  PD Event ) ( PD Event  PP1 Event ) ( PP1 – M/P Event )
o Event PP2 Go dan Mass
Pro mendapatkan
penilaian di bawah
standar minimal *Sumber : Email Marketing Perihal Penilaian Part Development

penilaian Part JUDGEMENT SCORE FINAL SCORE

Development. VERY GOOD
GOOD
90 < x ≤ 100
75 ≤ x ≤ 90 TEMA
FAIR 50 < x < 75
POOR x ≤ 50
*Standar minimal penilaian Part Development MENINGKATKAN PENILAIAN PART
PADA SETIAP EVENT NEW MODEL
AHM (TARGET >90)
Background

AHM ‘S FLOW PROCESS PROJECT HANDLING INTERSECTION WITH DPP’S FLOW

PROCESS

Phase Die
Phase T0 Phase PP1 Phase PP2 Phase PP3 MASS
GO

EKSTERNAL

FLOW PROCESS PROJECT HANDLING

Event Event D Event PP1 Event QAN & Event MP
G PP2

START A00 A06 A07 A13 A14 A18 A21

A20

A02 A01 A09 A08 A16 A15 A19

A03 A04 A10 A11 A17

A20

A05 A12

INTERNAL
 Background

GLOSARIUM

Istilah Keterangan Istilah Keterangan Istilah Keterangan Istilah Keterangan

Trial one (T1) & another
A00 Kick Off Project A07 Proposal Maker Layout A14 A21 Mass Production
Trial ( T1=Tn)
Draft Document for Material Handling & QAN S/C For
A01 A08 A15
Investment Calculation Facility Part/Component
Investment Plan/Re-
Bill of Material (BOM)
A02 Investment Plan [If Any A09 Layout Production Plan A16
Release
ECN]
Standard Measurement Pre-Production PP0 
A03 Feasibility Study A10 A17
tools equipment PP1
QAN ( Customer) For
A04 Pending / Cancel Project A11 Budgeting & PR release A18
product
Trial Nol (T0)  Trial
A05 Die Go [Internal]/ Die GO A12 A19 Handover Project
Event
List Machine, Tooling & Pre-Production 2 (PP2 …
A06 A13 On Job Training [OJT] A20
other Requirement PPn)
 Problem Anaylsis and Root Cause Analysis

Root Cause
WHY WHY ANALYSIS ALTERNATIVE
NO PROBLEM ACTIVITY PLAN
WHY 1 WHY 2 WHY 3 WHY 4 WHY 5 WHY 6 SOLUTION
Pemenuhan Ada revisi desain Kualitas packaging Follow up ke maker Progress review Pembuatan
Packing tidak packing tidak sesuai packaging lama new product dashboard control
sesuai timeline spesifikasi development project yang dapat
1 project bersama diakses oleh
management semua
departemen terkait

Pemenuhan subjig Ada revisi desain Kualitas subjig tidak Follow up ke maker Progress review Pembuatan
tidak sesuai timeline subjig sesuai spesifikasi subjig lama new product dashboard control
project development project yang dapat
2
bersama diakses oleh
management semua
departemen terkait
Hasil painting NG Hasil finishing Operator kurang Tidak ada alokasi Alokasi MP tetap
raw part overcut/flashing paham kualitas part MP ketika event oleh produksi untuk
dan proses finishing project mendukung trial
event
Line painting Sirkulasi udara Preventive Maintenance belum Progress review
terkontaminasi painting tidak maintenance belum mengerti urgensi new product
RSP NH-1 dibawah bintik warna metalic baik/lancar berjalan rutin sesuai kondisi mesin development
3
20% jadwal terhadap new bersama
Hasil painting NG Line painting dan project management
bintik kotor subjig kotor Aktivitas cleaning Poin-poin cleaning Dept. painting
kurang maksimal kurang dipahami belum mengerti
oleh operator urgensi kebersihan
cleaning line terhadap new
project

: Root Cause
Engineering’s Main
Job on Jishuken
Engineering’s Jishuken Roadmap

Target Step 1 : September 2023

Step 1 (Basic)
• Berfokus kepada keteraturan project dan menjaga project on Target Step 3 : Februari 2024
schedule dengan koordinasi antar departemen based on Step 3 (Terbiasa)
document. • Implementasi OBEYA room untuk identifikasi setiap progress
• Membudayakan project meeting rutin bersama management beserta problem yang muncul pada setiap project
untuk menjaga customer satisfaction terhadap new project • Melibatkan peran aktif setiap departemen pada Obeya room
progress untuk dapat Ikut andil dalam mendorong keberhasilan new
Target project dengan kriteria “On time schedule” dan “High grade
JISHUKEN EPS”
1
2
3
4

Step 2 Step 4 (Budaya)

• Berfokus kepada kesesuaian document dengan
standard new product development standard sesuai
dengan PIC.
• Project meeting rutin menjadi budaya perusahaan
Target Step 2 : Desember 2023
• Keterlibatan setiap departemen di OBEYA room dan dapat
membuat OBEYA room sebagai tempat brainstorming
bersama management
• Decision Making Bersama management dapat dilakukan di
OBEYA room
• Penilaian performa setiap departemen pada project new
product development
Engineering’s Jishuken Roadmap

Target Step 1 : September 2023

Target Step 3 : Februari 2024

1
2
3
4

Target
JISHUKEN
Step 2 Step 4 (Budaya)
• Berfokus kepada kesesuaian document dengan • Keterlibatan setiap departemen di OBEYA room dan dapat
standard new product development standard sesuai
membuat OBEYA room sebagai tempat brainstorming
dengan PIC.
bersama management
• Project meeting rutin menjadi budaya perusahaan • Decision Making Bersama management dapat dilakukan di
Step 1 (Basic)
Target Step 2 : Desember 2023 OBEYA room Step 3proje
• Berfokus kepada keteraturan (Ter
•
• Penilaian performa setiap departemen pada project schedule
new dengan koordinasiImpleme
antar d
product development document. beserta
• Membudayakan project• meeting
Melibat ru
 End Goal Strategic Map & Action

Strategy Map Objective Measurement Target PIC

Financial Perspective

Revenue Growth

Customer Performance Development Judgment Score 90 Team Project

Excellent Project

Internal Process Compliance & Ontime setiap event Sesuai dengan objective Target 100 Team Project
Project project
Improve Project Management
management Dashboard Evaluasi Project

Review Business Create Process

Flow Process identification &
Analysis Cross
Function

Learning Growth Skill & Competency Up Matrix Competency Mandatory Level Team Project
100%
Software
Program Training
Skill Up
engineering
Competency

Investment Digital Dashboard Running & Complete 100 % Run Team Project

Application
software
 Aktifitas Rencana Perbaikan

TIMELINE
NO AKTIVITAS MARET APRIL MEI JUNI JULI AGUSTUS SEPTEMBER OKTOBER
W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

1 Menentukan tema

2 Analisa kondisi saat ini & target

3 Analisa akar masalah

4 Membuat rencana perbaikan

I. Prosedur New Project Management

Re-Look project management System (Back to

Basic)

Alur Tahapan Project

SO Company project leader beserta Job Desc

dan Dept In Charge

Evaluation Readiness Review

II. Membuat system control Project

5 Pelaksanaan Perbaikan

6 Evaluasi

7 Standarisasi

Visualisasi Engineering Project [OBEYA] (Next

8
PDCA) TARGET 2024
 Aktifitas Rencana Perbaikan

Key Performance Mengacu Mekanisme Penilaian Customer (AHM)

Strategic Improvement Key Success Factor

Konsistensi PDCA

Improve
KPI
Project Category Performance
Management Excellent setiap event
project 100 point

PP1 Go /
EVENT D E1 E-1 Event QAN MP
PP1.2 Go
CATEGOR
Y
EXCELLENT

POINT 100 100 100 100 100 100

 Aktifitas Rencana Perbaikan

Re-Look project management System

Base On Prosedur new project

3 4
Flow Chart 1
SO Project
Tahapan Event Project

New Product
Readiness Review

2
Defined Main Requirement for Project event

Visualisasi Engineering Project

[OBEYA]
 Aktifitas Rencana Perbaikan

NEW PRODUCT READINESS EVALUATION

PROJECT NAME :
REVIEW DATE :

DOCUMENT PROJECT REQUIREMENT (HIERARKI)

LEVEL 5 LEVEL 4 LEVEL 3 LEVEL 2 LEVEL 1

O O O DUE
EVENT TARGET 0% 0% 0% PROGRESS ALL LEVEL COUNTER MEASURE PIC
X DATE
O X 33%
50% 50% O
X X X 67%
100% 100% 100%

Similarity Study ENG 1,32 X 1

QA Matrix QA/QC 5,00 X
Study Problem History/Kakotora QA/QC 5,00 X 2

Study Abnormality Process dan

QA/QC 5,00 X 3
Potensi Kegagalan (FMEA) 17%
Study Manufacture Quality
ENG 1,32 X 4
Standard (MQS)

Draft Mapping Flow Process Plan

1 Hearing Pass (MFPP)
ENG 1,32 X 5

83%
Draft Process Quality Control Supplier Quality Assurance
ENG 1,32 X Draft Quality Guarantee Planning QA/QC 5,00 X MKT 2,78 X 6
Sheet (PQCS) Manual/QAS

Customer Engineering Standard MKT 2,78 X 7

Current Production System Study

PPIC 8,33 X 8
Similiar Model X O
5M Analysis ENG 1,32 X Capacity Confirmation (FKK) PPIC 8,33 X
Draft Loading Capacity Planning PPIC 8,33 X 9

New Product Development LV5 67%

Pending/Canceled Project (A04 MKT 2,78 X 10
Sheet)*
New Product Development
MKT 2,78 O Price & Quotation MKT 2,78 O
Planning Notice (A00 Sheet)
LV4 50%
Financial Feasibility Study MKT 2,78 X

G Technical Feasibility Study ENG 1,32 O

LV3 0%
Seppen aplikasi on
2 Manufacture Control Plan ENG 1,32 X General Schedule Customer MKT 2,78 X Draft Layout Production Size Plan ENG 1,32 O
schedule Die Go Letter/Letter of Intents
MKT 2,78 X
(LoI) (A05 Sheet)
Draft List Material Handling &
ENG 1,32 O
Facility LV2 0%

Draft List Tools, Dies, Jig, Fixture

Draft Budget Investment Plan ENG 1,32 X ENG 1,32 O
Need & OH/IH

Draft List Machine, Equipment, &

ENG 1,32 X LV1 0%
Consumable for Machine

Draft List Standard Measurement

QA/QC 5,00 X
Tools Equipment 0% 20% 40% 60% 80% 100%

Study Drawing ENG 1,32 X Drawing Specification MKT 2,78 X

Output Study
1
Drawing
Draft List Part/Material OH/IH ENG 1,32 X

Seppen teraplikasi Kontrol History Perubahan

2 Seppen
ENG 1,32 X
pada MCP
IPP Request, Control &
ENG 1,32 X
Evaluation

Hinanhyo sudah Review & List Up Current

3 ENG 1,32 X
dibuat Material Specification/Material
Material
ENG 1,32 X
Confirmation
Review MSDS, ROHs, refer to
ENG 1,32 X
GADSL & HCSMS

PESERTA :
Dib u a t , / / Dise t u ju i Dike t a h u i
LV5 LV4 LV3 LV2 LV1

X 11,00 X 10,00 X 5,00 X 2,00 X 2,00 30,00

O 0,00 O 0,00 O 0,00 O 2,00 O 4,00 De w a M a d e S.

6,00 Eko M a ry a n t o
De p t . M a rke t in g De p t . M a in t e n a n c e De p t . PPIC De p t . Pa in t in g De p t . En g in e e rin g De p t . Pro d u ksi Div isio n He a d M fg . Pre sid e n Dire kt u r
X O