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GEMBA MANAGEMENT
Standardization
&
Quality Assurance
Policy
Management
Cross-
Functional
Management
Daily
Management


Suggestion
System
Quality
Control
Circle
5 S
2/15
Gemba Management in
Company Management
TOP
MANAGEMENT
MIDDLE
MANAGEMENT
SUPERVISOR
FOREMAN &
OPERATOR
GKM
3S
5R
3/15
5R IMPLEMENTATION
WAY TO DEVELOP
WORLD CLASS COMPANY CULTURE
5S
Seiri
Seiton
Seiso
Seiketsu
Shitsuke
5C
Clear-out
Classify
Cleaning
Conformity
Custom
5R
Ringkas
Rapi
Resik
Rawat
Rajin
5P
Pemilahan
Penataan
Pembersihan
Pemantapan
Pembiasaan
4/15
5R IMPLEMENTATION
OBJECTIVES
To create a comfortable workplace and
interesting job
To train employee independently organize his/her
work
To enforce discipline is using standard
To create Visual Factory
Create positive image upon customer view
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EFFECT ON 5R IMPLEMENTATION
Minimize the potention of:
Accident
Breakdown
Cost
Defect
Increase efficiency and work motivation
A ready organization for transformation in
direction of Top management strategy
6/15
TRANSFORMATION:
BEHAVIOR & WORKPLACE CONDITION
Workplace
Workplace
Behavior Attitude
Behavior Attitude Culture
5R IMPLEMENTATION
Customs
( 3 principles : Consistency, Continuity & Simplicity)
TRAINING
7/15

SUGGESTION SYSTEM
Definition

Management system that involves every
customer in improving quality through
individual suggestion for improvement
8/15
SS DEVELOPMENT IN JAPAN
(1984)
THE BIG TEN GROUP IN SS IMPLEMENTATION
Matsushita (Panasonic) 6.58 million
Hitachi 4.65 million
Mazda 3.06 million
Toyota 2.15 million
Nippondenso 1.43 million
Mitsubishi Motors 1.12 million
Nissan Motor 1.07 million
Aisin Seiki 0.97 million
Bridgestone Tire 0.95 million
Japan National Railway 0.78 million
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SS IN TOYOTA MOTOR CORP.
(1984)
Number of suggestion : 2.1 million
Number of suggestion/ employee : 40
Participation level: 95%
Acceptance level: 95%
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COMPARATIVE STUDY ON SS DEVELOPMENT
IN AMERICA AND JAPAN (1989)
USA Japan
Number of people implementing SS 282 666
Number of employee involved 8.642.269 1.646.960
Number of suggestion accepted 996.694 60.343.937
Number of suggestion /100 employee 12 3.664
Number of employee suggest /100
employee 9 75
Adoption rate 32% 87%
Rerata award/adoption $602.15 $2.20
Rerata economy/adoption $6.114 $110
Economy/ 100 employee $22.825 $365.656
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THE DIFFERENCE OF SS
WEST VERSION AND JAPAN VERSION
West (America)
Emphasize on economical
output( great ideas)

Extremely put emphasis on
Financial incentive
Personal motivation

SS Committee
responsibility
J apan
Emphasize on participation
(small ideas)


Psychological Incentive
(pengakuan dan aktualisasi
diri)
Personal motivation and
group
Top management
responsibility
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SS OBJECTIVES IN MANAGEMENT
Suggestion system ideas can be directed for:

Ideas to increase sales
improve servicing, product image, product selection,
exhibition method, etc

Ideas to lower cost
efficient work, reduce non-quality product; overtime
work, wastes; inconsistency; etc
13/15
SS IMPLEMENTATION STRATEGY AND MECHANISM
Suggestio
n
system
Mechanism
Strategy
System
Organization
Regulation
Reward System
Standard Evaluation
Suggestion Form
Education and Training
Campaign
Promotion activity
Motivation encouragement
Coaching and Counseling
14/15
QUALITY CONTROL CIRCLE
Definition
Group consist of operators with specific job who
meet together periodically to discuss and solve
problems and the job environment with focus on
improving quality using quality control system
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QUALITY CONTROL CIRCLE
OBJECTIVES
Improve problem- solving ability
Increase involvement of employee in problem solving
Promote teamwork in the group
Increase awareness of problem prevention
Increase employee motivation
Increase communication in the group
Improve Top-Bottom relationship
improve quality