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CURRENT CONDITION

LATAR BELAKANG

CLAIM & KOMPLAIN (INTERNAL & EKSTERNAL PELANGGAN)


PENINGKATAN KUALITAS (QUALITY, DELIVERI & COST)
CONTINUEUS IMPPROVEMENT SYSTEM
PENINGKATAN KEUNGGULAN PRODUK
CAPEK HASIL
ORANG PERGI = PRODUK PERGI

SIDE TIP CASE


KASUS SIDE TIP
CLAIM & COMPLAIN
MASALAH DI LAPANGAN (VISIT REPORT)
QUALITY (QUALITY, DELIVERY & COST)
VALUE
LOSS DEAL

VISIT REPORT

MOM

SIDE TIP CASE


PENYEBAB (INTERNAL)
DESIGN ENGINEERING
DESIGN PRODUCT KURANG HANDAL
STADE THE ART DESIGN BELUM TERCAPAI
KOMPETENSI & KAPASITAS
DRAWING & BOM BELUM SEMPURNA
LIBRARY (DATA) KURANG
PRODUCT ENGINEERING BELUM ADA
PROSES KOMPONEN
PROSES FABRIKASI
PPC
EFEKTIFITAS & EFISIENSI PENJADWALAN KURANG
PRODUCTION
ORIENTASI KUALITAS KURANG
WASTE TIME TINGGI (REJECT, PENGELASAN DOBEL)
KOMPETENSI & KAPASITAS KURANG
FACILITY KURANG
PRODUCT SPECIALIST
KOORDINASI DG FINANCE (DUKUNGAN FINANCE)

SIDE TIP CASE


PENYEBAB (EKSTERNAL)
PROCUREMENT
KEKUATAN PEMASOK MASIH KUAT (SKALA PRIORITAS LEMAH)
PENJADWALAN KEDATANGAN KURANG DETAIL/FIX
FINANCE
DUKUNGAN FINANCIAL KURANG
QUALITY ASSURANCE & CONTROL BELUM JALAN BAIK

GOAL/OBJECTIVE
RINGKASAN
JOB DESCRIPTION HARUS DIBAKUKAN
FLOW BUSINESS PROCESS HARUS DIBAKUKAN
ORIENTASI KEPADA KUALITAS PERLU DITINGKATKAN
KEMPETENSI & KAPASITAS PERLU DITINGKATKAN (MATRIK KOMPETENSI)
PENINGKATAN FASILITAS PABRIK
KOORDINASI (PERTEMUAN RUTIN) Perlu ditingkatkan (Shearing Knowledge)
(Marketing meeting, Production Meeting, dll)
REPORTING & PENILAIAN KINERJA BELUM JALAN

GOAL/OBJECTIVE
TUJUAN PROGRAM
Program Perbaikan Berkelanjutan
Program Re-Engineering (Management System)
Internal Bussiness Process
Job Description Standard
Memastikan Sistem Berjalan
Penentuan Ukuran Kinerja
Pengukuran Kinerja

GOAL/OBJECTIVE
TUJUAN IBP
KEUNGGULAN PERSAINGAN (KOMPETITIVE ADVANTAGE)
UNIK
KEPUASAN STOKEHOLDER
Pemegang Saham
Pelanggan
Karyawan
INOVASI (PRODUK & PROSES)
KUALITAS
KUALITAS PRODUK (QUALITY)
BEAYA (COST)
WAKTU (CYCLE TIME)

DEFINITION
INTERNAL BUSSINESS PROCESS
Merupakan kelompok-kelompok dari keputusan-keputusan yang terkait dan
kegiatan-kegiatan yang dibutuhkan untuk mengelola sumberdaya-sumberdaya
bisnis (M/P, Peralatan, Fasilitas, Bahan dll)
Urutan beberapa aktifitas yang saling berhubungan untuk merubah masukan bisnis
menjadi keluaran bisnis.
Masukan: Bahan Material, Peralatan, M/P dll
Keluaran: Produkc/Barang, Jasa/Service

VALUE & QUALITY


RELEASE VALUE & QAULITY DETERMINATION

INTERNAL BUSINESS PROCESS


1. Management System

BSC Methodology
Alignment Mission, Vision, Goal, Strategy to day to day operation
Financial, Customer, Internal business process, Innovation & Learning

Streamline Business Process

Industry Supporting & Infrastructure

IT System Infrastructure

2. Quality Assurance System

Business Process Flow & Documentation

Target ISO 9001

3. Manufacturing System

Jig & Fixture

Manufacturing Automation

I/O IDENTIFICATION
IN PUT OUT PUT IDENTIFICATION

INTERNAL BUSINESS PROCESS PRACTICE


1. INTERNAL BUSINESS PROCESS FLOW
2. JOB DESCRIPTION
3. QUALITY ASSURANCE
4. ORGANIZATION STRUCTURE

BUSINESS PROCESS
PORTER ANALISYS

GENERIC MODEL

Business & Product Development


Human Resources

Customer Value

Finance & Accounting

Q U A L IT Y
A SSUR ANCE
M A R K E T IN G
A D M IN IS T R A T IO N

People Value

P R O D U C T IO N

P R O D U C T IO N P L A N
P U R C H A S IN G

E N G IN E E R IN G

M A R K E T IN G

Management Information System

Shareholder Value

MODIFICATION MODEL

Marketing & Sales


Resource
Labor cost
Manpower
Kondisi market (survey)
Harga komponen

quotation (penawaran harga)


Membuat
Laporan production capacity

customer
and
customer master
Quotation
data
Maintain
Data histori
spesifikasi
produk
Customer History
forecast order
Membuat

Membuat pricing product


Work

Forecast of market

Inquiry (permintaan
pelanggan)
Specification
of pelanggan
product
dan membantu
claim and
return dari
Memantau
Customer task and contact
Invoicing

SO (sales order)

PPC requirement

Menciptakan pangsa pasar baru Quality


Quality

Input

Requirement Response time


Promosi produk (Iklan dan pameran)
Clear Task

Environment

Environment

Demography of customer

Customer Visit

Box of Process

Output

Engineering

Resource
Labor cost
Manpower

Resource

Hardware & software

Engineering cost

Design
& Improvement
Design cost
Part
& product
specification of Product
Product
Development
Part
& Product
price (budget)

Improvement
old product
Material
list
Product Survey

Work
Drawing design

Work

Bill of material

Sales Order

GA: Estimasi Berat Struktur

Release drawing, BOM & specification sheet

Capture technical specification for affco & supplier

Job Order

Quality Improvement

Quality

Quality

Clear of Product Specification

Design Error

Part Specification

Design Release

Environment

Environment

Sales Forecast

Data available

Prototyping

Input

& Komponen List

Design documentation

Box of Process

Output

Product Engineering

Resource
Labor cost
Manpower

Resource

Hardware & software

PE cost

DesignDesign
Material
Preparation Process
Manufacturing Design cost
Drawing
& BOM
DesignSpecification
Fabrication Process
Machine
M/H
Calculation
Std
calculation
(M/H)

Machine/Hour Calculation

Work
Lbr Proses Persiapan Bahan

Work

Lbr Proses Fabrikasi

Job Order

Lbr Proses Assembling

PPC scheduling

Nasting

Quality

Quality

Clear of DWG Design & BOM

Design Process Error

Target Jig

Design Process Release

Environment

Environment

Production Facility

Data available

Design Jig

Monitoring & Support Material Preparation


Monitoring & Support Fabrication
Nasting Plate

Input

Box of Process

Output

Production Plan and Control


Resource
Labor cost
Manpower
Hardware & software
Forecast

Resource
PPC cost

BOM
Supplier, subcont, man power,

Certify supplier & sub-cont

inventory data

Work
Perencanaan produksi dan pembelian

Work

Purchase schedule

Sales Order, PO

Production plan schedule

Forecast

Process daily report

Memonitor dan mengkontrol produksi harian


Menjaga inventory

Sub-cont visit report

Quality

Input

Forecast

Quality

BOM

Efektifitas & efisiensi

Environment

Environment

Lead Time (Sub Cont & Supplier)

Inventory Cost

Box of Process

Output

Manufacturing

Resource
Labor cost
Manpower
Design drawing, LPPB, LPF, LPA
Prosuction plan scheduling
Product specification & BOM
Material & Component data

Resource

Data subcontractor

Production cost

POmaterial, etc)

Work

Product cost
Manage resource (manpower, facility, machine,
Work
Production schedule
JO
Release production scheduling
Finish product
Quality
Production procedure & assembling
Production time report
Reject
Part
&
Component
Ensure product quality
Variant Design

Maintain equipment

Input

Environment

Quality

Product reject/fail
Cost of quality

Sales Forecast

Environment

Variance

Procedure Error

Design Error
Machine Availability

Box of Process

Output

Quality Control

Resource
Labor cost
Manpower

Resource

Design drawing

Quality control cost

Production plan scheduling

Check list product

Bertanggungjawab
terhadap penentuan kualitas
Product
specification
Work
Quality
planning
akhir produk
Release product
Memastikan kualitas produk sesuai
Work
Qualitydengan
report
PO

Input

perencanaan

Check list report

Quality

Quality

Product Specification

External failure

Environment

Environment

Customer Expectation

Template of Finish QC

Box of Process

Output

Marketing Administration
Resource
Labor cost
Manpower

Resource

Deivery schedule

Delivery scheduling

Customer data Packing

Cost of MAD

Forwarder data
Forwarding agent Work
Production report
Transportation
Delivery of product report
Work
SO, PO
Forecast
Quality

Import taxes

documentation
Import & export procedure

Costing

Unit inventory report in yard

Quality
Unit inventory report

Delay Finish Product

Input

Export & Import

Export document

Environment

Delay product delivery


Individual Voyage (shipment)

Shipment Schedule

Environment

Customer Data

Invoice

Box of Process

Output

INTERNAL BUSINESS PROCESS


FLOW OF BUSINESS PROCESS
MARKETING
ENGINEERING

PRODUCTION CONTROL

PROCUREMENT

MANUFACTURING

QUALITY ASSURANCE

MAD

SERVICE &
PRODUCT SUPPORT

CUSTOMER

INTERNAL BUSINESS PROCESS


ORGANIZATION STRUCTURE
BOARD OF COMMISSIONERS
BOARD OF COMMISSIONERS
BOARD OF DIRECTORS
BOARD OF DIRECTORS

BUSINESS & PRODUCT


BUSINESS & PRODUCT
DEVELOPMENT
DEVELOPMENT

QUALITY ASSURANCE
QUALITY ASSURANCE

LEGAL
LEGAL

R&D
R&D
MIS
MIS
MARKETING &
MARKETING &
CUSTOMER SUPPORT
CUSTOMER SUPPORT

PPIC
PPIC

ENGINEERING
ENGINEERING

MARK. REP
MARK. REP

Production Control
Production Control

ENG. DESIGN
ENG. DESIGN

PART & SERVICE


PART & SERVICE

Purchasing
Purchasing

Manuf. Eng
Manuf. Eng

MARK. ADM
MARK. ADM

Inventory Control (W/H) Application Eng


Inventory Control (W/H) Application Eng

MANUFACTURING
MANUFACTURING

FINANCE &
FINANCE &
ACCOUNTING
ACCOUNTING

HRD &
HRD &
GENERAL AFFAIR
GENERAL AFFAIR

Persiapan Bahan
Persiapan Bahan

Finance
Finance

HRD
HRD

Fabrikasi
Fabrikasi

Accounting
Accounting

GA
GA

Assembling
Assembling
Painting
Painting
Quality Control
Quality Control

Flowchart of Engineering
MARKETING

PRODUCTION

ENGINEERING

Awal

Survey
Kebutuhan
Pelanggan

Standard Spect.

ok

Spect.
standar
no
Product Spect.

Design Development
Plan & Review

Buat Concept

Buat Preliminary
Lay out

PRODUCTION CONTROL

QUALITY ASSURANCE

MARKETING

PRODUCTION

ENGINEERING

PRODUCTION CONTROL

QUALITY ASSURANCE

Drawing

Drawing

Final Design

Drawing
Specification Sheet
BOM

Drawing
Specification Sheet

BOM

Spect. Sheet

BOM

ok
Modification
no
Prototype

TEST

no

ok
Validation Report

Validation Report

Validation Report
AKHIR

TERIMAKASIH