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SHOPFLOOR BEST PRACTICES
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
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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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5S Program
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5S Program
a. Impleme
nt Short
b. Impleme
nt Set in
order
c. Impleme
nt Shine
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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
5S Program
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5S Program
To keep continuing 5S campaign to all employies by 5S Training;
Opening Refreshment 5S by Pak Isack
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5S Program
Training-Audit sesion
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5S Program
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
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5S Program 5S Recognition Board:
Area name
Period of audit
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5S Program
Develope and upgrade the checklist
For 5S Audit
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5S Program
•Inauguration of 5S Auditor (Confirmation as 5-S auditor in CBN)
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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 )
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SHOPFLOOR BEST PRACTICES
Devide Plant Cibinong and Cikampek to some area 5S
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5S Program
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5S Program
•Result Audit 5S Period September 2009 Cibinong
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5S Program
Monthly Recognition Event
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5S Program
Yearly Recognition Event
For 5S WINNER
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4 Activities:
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a. Selection The Group Leader
Review Organization Structure
a.Selection The Group Leader
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b. Comprehensive Training
38 Training Modules
Make more and
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
5S Training
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
Fantastic Games
Self Reflection
Graduation
Graduation
SHOPFLOOR BEST PRACTICES
c. Review Group Leader Performance
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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
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d. Shop Floor Management Coaching (SFMC)
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d. Shop Floor Management Coaching (SFMC)
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Achievement Score for Group Leader Coaching
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SHOPFLOOR BEST PRACTICES
dj
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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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SFM
SFM
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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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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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Q-sign picture
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Cibinong Cikampek
C o a te d F o rm in g
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SHOPFLOOR BEST PRACTICES
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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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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