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OJD
Activity-5
(Batch #2)
BACKGROUND
ConstructionMDT Cabin
of Unit PlantSix Segment
Total Demand Trend of Indonesia Commercial Vehicle The immediate
(1,000 unit/year) recovery exceed
our assumption
147 Down by half 95
from ’12
Highest 73
Record
2011 2012 2013 2014 2015 2016 2017 2019 2025
Kick Off
OJD
Activity-5
(Batch #2)
Directorat Production Target
1. Management Target [ FM8J, RK8J & 130HD ]
TARGET ΣCT FY2025 ΣCT TARGET 2025 :
369310
400000 50% 60%
339765
310220 45% 48% TO IMPROVE PRODUCTIVITY
280676 39% 50%
300000 251131
32% 225279
203121 192041 40% 50% UP WITH ZERO WORK
24% 184655
200000
16%
30% ACCIDENT AND ZERO KURO
20%
100000 8% BATSU BATSU (SQA)
0% 10%
0 0%
Apr-18 FY2018FY2019FY2020FY2021FY2022FY2023FY2024FY2025
KAIZEN CONCEPT
Step 0 Step 1 Step 2 Step 3
Unstable Process Visualize abnormality Kaizen 1 Kaizen 2
Eliminate Difficult job Reduce Muda Reduce Non-Value Job
(Mura, Muri)
Stable Process Kaizen Result
Muda
Reduced
Non Value
Muda Muda
Reduced
Muda
Muda
Smooth Slim
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OJD
Activity-5
(Batch #2)
Spirit Kaizen
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OJD
Activity-5
(Batch #2)
DEPT. KADAI LIST
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OJD
Activity-5
(Batch #2)
ABILITY MAP
Metode evaluasi
評価方法 Evaluation way Before Training After Training Remark
Evaluasi Evaluasi 0~5 Evaluasi 0~5
Target
・Evaluasi berdasarkan 6 tahapan Tanggal Evaluasi 15-Apr-19
・基本的に6段階評価 Basicaly evaluate 6 stage Basic TPS 2 3
MIFC 2 3
0:Belum pernah mendengar / tahu 7 Muda 2 3
0:聞いたことがない Never heard of it SW 2 3
Belum pernah membaca 4M 5 Why 2 3
読んだことがない Never read of it Kaizen Motion 2 3
Yamazumi 2 3
1:Sudah pernah mendengar / Sudah mengetahui Origami 2 3
1:聞いたことはある I have heard it
Sudah pernah membaca Basic TPS
読んだことがある I have read it
Ability Map 5
Yamazumi 2 0 23 7 Muda
3
2
2 3
Member Trainier 3 2
3
Kaizen Motion SW
DETAIL ACTIVITY 96
LIBUR LEBARAN
3.2 Kaizen in genba-2nd (Method/Analysis) 4
Plan (24 Mei-20 Juni)
a. Make MIFC, Current SW & Video Current Process 11 Member
LIBUR PEMILU
Actual
Plan (21-26 Juni)
b. 19 View Point Kaizen Analysis 5 Member
Actual
Plan (27 Juni-3 Juli)
c. 4M + 5 Why Analysis 5 Member
Actual
4 Report 38
Plan (K/O 12 Juli )
a. Kick Off OJD (K/O) 1 Member
Actual
Plan (M/R 15 Ags )
b. Middle Review (M/R) 1 Member
Actual
Plan
c. Final Report 1 Member
Actual (FINAL 17 Sept )
5 HPID Check 3
96
PLAN
ACTUAL :
:
KICK OFF ACTIVITY MIDDLE REVIEW FINAL ACTIVITY
• WEEKLY CHECK HPID
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OJD
Activity-5
(Batch #2)
MIFC CURRENT
MIFC CURRENT CONDITION SMALL PART MDW
Next
Before Process Logistic
Process
Proses Storage Setting Preparation Delivery
Loading / Storage Storage
Supplier Receiving Loading Unloading Storage Logistic 1
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
Plant
DELIVERY
5
D-1
3
D-3
Supplier
1 X /day
Kontrol stok susah di Setting part tidak
lakukan dan lama berurutan dan lama
10.00 am
16 detik H 15
966 detik
22 18 10 4 D-7
13 detik 53 unit 23 detik 38 detik
1 X /month
27 25 14
12 detik G 1002 detik
21 17 9
MDW 53 unit 26 detik 41 detik
1218detik
1
13 Proses supply tidak
1025 detik 14 detik F berurut dan tidak
1080 detik 36 detik 7
20 16 sesuai permintaan
26 24 8
53 unit 22 detik 12
D
13 detik 952 detik
E 24 unit
5 A 12 unit
32 unit C
Loading / Storage Setting Preparation Delivery Storage Storage
TOTAL LEAD TIME Supplier Receiving Loading Unloading Storage Logistic 1 Total
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
c ❼ ❻ ❺ b ❹ ❸ a ❷ ❶
INFORMATION
134 782 5 28800 4320 5 5 10800 5 5 44861
27 25 23 22 21 20 19 18 17 16 11 10 9 8 6 4 3 2 1
CONVEYENCE
13 16 28 46 595 20 19 132 111 980
26 24 15 14 13 12 7 5
PROCESS
1080 1025 1026 1218 503 4852
H G F E D C B A
STAGNASI
28620 12960 17280 6480 65340
116033 Sec
LEAD TIME CURRENT 1933,88 Mnt
CURRENT 50693 65340 116033 PROSES
Total lead time
32,2314 Hour
STAGNASI 4,02892 Day
0 20000 40000 60000 80000 100000 120000 140000
SECOND
Kick Off
OJD
Activity-5
(Batch #2)
MIFC IDEAL
MIFC IDEAL SMALL PART MDW
Next
Before Process Logistic
Process
Proses Storage Setting Preparation Delivery
Loading / Storage Storage
Supplier Receiving Loading Unloading Storage Logistic 1
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
Plant
DELIVERY
5
D-1
3
D-3
Supplier
1 X /day
10.00 am
16 detik H 15
966 detik
22 18 10 4 D-7
13 detik 53 unit 23 detik 38 detik
1 X /month
27 25 14
12 detik G 1002 detik
21 17 9
MDW 53 unit 26 detik 41 detik
1218detik
1
13
1025 detik 14 detik
1080 detik
F 36 detik 7
20 16
26 24 8
53 unit 22 detik 12
D
13 detik 952 detik
E 24 unit
5 A 12 unit
32 unit C
Loading / Storage Setting Preparation Delivery Storage Storage
TOTAL LEAD TIME Supplier Receiving Loading Unloading Storage Logistic 1 Total
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
c ❼ ❻ ❺ b ❹ ❸ a ❷ ❶
INFORMATION
134 782 5 500 4320 5 5 500 5 5 6261
27 25 23 22 21 20 19 18 17 16 11 10 9 8 6 4 3 2 1
CONVEYENCE
13 16 28 46 595 20 19 132 111 980
26 24 15 14 13 12 7 5
PROCESS
1080 1025 1026 100 503 3734
H G F E D C B A
STAGNASI
100 100 17280 6480 23960
34935 Sec
LEAD TIME IDEAL 582,25 Mnt
Total lead time
9,70417 Hour
CURRENT
50693 65340 116033 1,21302 Day
PROSES
IDEAL
10975 23960 34935 STAGNASI
DELIVERY
5
D-1
3
D-3
Supplier
1 X /day
KONTROL STOK
SETTING PART
TERVISUALISASI
BERURUTAN SESUAI
DENGAN BAIK 10.00 am
SEQ
5 A 12 unit
32 unit C
Loading / Storage Setting Preparation Delivery Storage Storage
TOTAL LEAD TIME Supplier Receiving Loading Unloading Storage Logistic 1 Total
Unloading sub assy trimming frame final sub assy trimming frame final Logistic 2 Production
c ❼ ❻ ❺ b ❹ ❸ a ❷ ❶
INFORMATION
134 782 5 28800 4320 5 5 10800 5 5 44861
27 25 23 22 21 20 19 18 17 16 11 10 9 8 6 4 3 2 1
CONVEYENCE
13 16 28 46 595 20 19 132 111 980
26 24 15 14 13 12 7 5
PROCESS
1080 1025 1026 1218 503 4852
H G F E D C B A
STAGNASI
500 500 17280 6480 24760
2,6199 Day
IDEAL 10975 23960 34935 PROSES
STAGNASI
Forklift MR
Empty Pollybox
RECEIVING
1.TRIMMING PART
2. FINAL PART
WAKTU ( DETIK )
No URUTAN PEKERJAAN Cycle Time Frequensi CT/Day
1 RECEIVING CNK PART 2233 1 2233
2 RECEIVING PEMI / PASI 1348 2 2696
3 RECEIVING CNC PART 1963 1 1963
4 RECEIVING DCI & BSI Part 966 2 1932
5 RECEIVING MPI & AOP 1319 2 2638
6 RECEIVING AKU PART 578 1 578
7 RECEIVING MARUGO & CAJ PART 840 2 1680
8 RECEIVING CKPM & IRI PART 1081 2 2162
9 RECEIVING ATL & Chemco Part 714 2 1428
10 RECEIVING OHK & ADIKU Part 744 2 1488
11 RECEIVING KTS 475 1 475
12 RECEIVING ASMO [DS1] Part 646 1 646
13 RECEIVING BMC Part 628 1 628
14 RECEIVING PART BERDIKARI 652 1 652
15 RECEIVING CSI Part 473 1 473
16 RECEIVING PART PRCA 720 1 720
17 RECEIVING GMU Part 940 1 940
18 RECEIVING ISI Part 707 1 707
19 RECEIVING PART WIKA 676 1 676
20 RECEIVING PART ATI 1140 1 1140
DETIK 25855
TOTAL
MENIT 430,9
PERSENTAGE
Operator Prepared by, Prepared by, Checked by,
Saya sudah membaca & mengerti ,serta akan melaksanakan dengan penuh
tanggung jawab Date : Date : Date :
Kick Off
OJD
Activity-5
(Batch #2)
YAMAZUMI
29616
30000 28548
27914 27493 27384
27306 27238 27026
25855 25456 25456
25223 25073
24641
25000
20000
Second
15000
10000
5000
0
RECEIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL 1 S/A FINAL 2 POLYBOX 1 POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
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OJD
Activity-5
(Batch #2)
ANALYSIS VIDEO
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OJD
Activity-5
(Batch #2)
ANALYSIS MUDA
LINE : SMALL PART MDW MP 1
Process Analysis sheet(Value, Non Value) MODEL
PROCESS
: SMALL PART
: RECEIVING
FUNDAMENTAL TPS KAIZEN VIEW POINT
Pengaturan dengan
Interfere Process
Double Handling
Kerja bolak-balik
secara bersamaan
Postur Kerja NG
tidak sesuai
setiap rute
Inspection
butuhkan
model
ubah
kerja
T.T
NVW MUDA MURI MURA MUDA
DETIK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1 Jalan ke Receiving Area 580
2 Ambil Surat Jalan Yang Masuk (Di Bok DN & Surat Jalan) 1312 1551 1551
3 Jalan Ke Receiving Part 580
4 Receiving, Check Part dengan DN 8314 4210 4210
5 Jalan ke Receiving Room 580
6 Tanda Tangan Surat Jalan & Stempel 2840 1864 1864
7 Jalan ke Kanban Room 580
8 Serahkan Surat Jalan ke Member Kanban 1304 1560 1560
9 Jalan (Kembali Seperti Semula) 580
PROCESS ANALISYS
VALUE
0%
MUDA
47% NON VALUE
60%
0 13770 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 13770 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
11855 15336
20000 9278 9441 15468 9556
12085 16797 9500
17301 17297
DETIK
10000
15638 16178 16015 15141 15517
13770 14280 13080
5000 11116 9764 10196 9937 9837 10087
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
DRIVER 1
DRIVER 2
S/A FINAL
S/A FINAL
FRAME 1
FRAME 2
POLYBOX
POLYBOX
F/L 1
F/L 2
TRIMM 1
TRIMM 2
FINAL
RECEIVIN
G
2
1
2
Kick Off
OJD
Activity-5
(Batch #2)
LIST PROBLEM
Mengganti receive
Proses angkat part CNC ke kategory part dari
MDW dolly transfer berat 30kg small ke Big part Follow up ke supplier terkait
1 6230 METHODE 820 5410 Rondji 21/09/2019
SMALL PART masih diangkat manual dengan mengganti metode receive terbaru
(standard 14kg) packing speck
(polybox ke dolly)
Memindahkan
Follow up ke supplier terkait
MDW Double handling proses Proses setting dan
4 105906 METHODE metode receive terbaru (22 69553 36353 Rondji 14/7/2019
SMALL PART setting dan shopping shopping ke Plant 1
supplier)
(SWH)
Kick Off
OJD
Activity-5
(Batch #2)
THEMA & SUB THEMA
Thema
BERDASARKAN PROBLEM DIATAS, MAKA KAMI MENGGAMBIL THEMA
"PRODUCTIVITY UP"
SEBAGAI PILOT PROJECT PADA OJD INDIVIDU ACTIVITY
SUB THEMA
1. Reduce ƩCT 8%
2. Reduce Lead Time
4,11 hari → 2,68 hari
Kick Off
OJD
Activity-5
(Batch #2)
TARGET
Achievement Final
Reduce CT 8%
Achievement Middle Reduce MUDA 8% Value Non Value Muda
400000
8% 10%
350000
300000 29938 37506
250000
193673 163735 156167
DETIK
200000
150000
100000
180556 180556 180556
50000
0
Current Target Achievement Final
Achievemen
t Final 32167 24760 2,09 Day
Plan
1 Design Kaizen Plan
Actual
Plan
Preparation
2
Materials
Actual
Plan
3 Kaizen Activity
Actual
Plan
4 Trial
Actual
Plan
5 Evaluasi
Actual
Plan
6 Standarisasi / SOP
Actual
Plan Actua
Kick Off
OJD
Activity-5
(Batch #2)
SCHEDULE KAIZEN ACTIVITY
PT. HINO MOTORS MANUFACTURING INDONESIA Mengetahui Disetujui Diperiksa Diperiksa Mengetahui Disetujui Diperiksa Dibuat
HINO PRODUCT INVESTIGATION DIVISION
Schedule Kaizen Activity OJD MDW Small Part U Tribudi Wisnu B P Ariyanto Rensy / Romadhon Chandra M A Ramadhani Raharjo A Rondji
PLAN
NO AREA PROBLEM ƩCT ILLUSTRASI 4M CATEGORY COUNTERMEASURE DESIGN KEBUTUHAN TARGET REDUCE PIC Harian / HOT
Jul-19 Aug-19 Sep-19 PROGRESS REMARK
AKTUAL W4 W5 W1 W2 W3 W4 W1 W2 W3 W4
Plan
I. KICK OFF ACTIVITY KE Mr.TIMBUL DAN Mr.KAZUSHI EHARA
Aktual
(K/O 22 Juli )
PLAN ( 5 - 16 Agust)
Layout area yang belum
Relayout area MDW
MDW SMALL di stadardkan sehingga cat putih dan hijau, Harian +
1
PART MP harus mencari lagi
17118 METHODE Small Part berdasarkan
Thinner, Kuas
2853 14265 A Rondji
HOT Hold 2Minggu
customernya
part yang mau di Setting AKTUAL
Plan
II. MIDDLE REVIEW (50% KADAI LIST SELESAI) KE Mr.TIMBUL DAN Mr.KAZUSHI EHARA
Aktual
(M/R 29 Ags )
PLAN (2 - 4 Sept)
Level Stock MDW Masih
MDW SMALL Distandardkan ke stok 1 Koordinasi dengan
4 menggunakan stock 2 METHODE 0 A Rondji Harian
PART shift (2,5 Hari) kanban Logistic
shift (4hari)
AKTUAL
PLAN (9 - 12 Sept)
Proses angkat part ke Pemindahan destinasi
MDW SMALL dolly transfer berat 30kg part dari MDW ke SWH Koordinasi dengan
5 4261 METHODE 0 4261 A Rondji Harian
PART masih diangkat manual karena di SWH sudah supplier
(standard 14kg) memakai Tools AKTUAL
Plan
III. FINAL REPORT KE Mr.TIMBUL DAN Mr.KAZUSHI EHARA
Aktual
(FINAL 27 Sept )
PLAN : Estimasi Saving Area
ACTUAL : = 42 m² x Rp 86.000,-
= Rp. 3.612.000,- / Month
Total Saving
= Rp 3.612.000,- + Rp 16.070.890
= Rp 19.692.890,- / Month
Kick Off
OJD
Activity-5
(Batch #2)
ILLUSTRASI KAIZEN ACTIVITY
Strategy & Kaizen Activity ( Reduce CT )
1. Pengelompokkan Part
Before
LOG
PICKING PART After
LOG
PICKING PART YAMAZUMI MP SMALL PART MDW
SA FR SA TR FN FR SUB ASSY
(Achievement)
35000
VALUE NON VALUE MUDA Reduce TAKT TIME
DETIK
15504 15263 15151 15259
12990
15000
TRIMMING
FN TR SA SA FR FN
10000
part dikarenakan penempatan part di area small Mengelompokan part berdasarkan line proses, 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
part tercampur dan tidak ada standard sehingga bisa mengurangi langkah operator REC EIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL S/A FINAL POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2
1 2
F/L 1 F/L 2
14
FRAM S/A S/A FINAL TRIM TRIM TRIM LH TRIM LH TRIM RH TRIM RH
After REDUCE AREA (3,7mx29,7)
LEAD TIME
13
12
FRAM FRAM S/A S/A FINAL TRIM TRIM TRIM LH TRIM LH TRIM RH TRIM RH
11
11
10
10
CURRENT 50693 65340 116033
RACK SPECIAL
9
RACK SPECIAL
8
8
7 7
6 6
5 5
3
4
3
REDUCE 1,43 Day
2
2
1
1
Rack Special Temporary Storage Rack Special Temporary Storage 0 50000 100000 150000
SECOND
PROSES STAGNASI
30000
T.T : 28200"
DETIK
13491
14236 13995 13883 13991
15000 9592
10000
Belum ada adrresing sehingga MP harus Dibuatkan addressing dan disesuaikan 5000
11116
9764 10196 9937 9837 10087
mencari cari part yang mau dipakai dengan urutan pengambilan part 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
REC EIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL S/A FINAL POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
1 2
25000
1268 1268
2131 15336
9278 9441 15468
20000 8549 8288
8232
2130
DETIK
7823 13491
14236 13995 13883 13991
15000
7462
Proses angkat part ke dolly transfer Pemindahan destinasi part dari MDW ke 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
RECEIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL S/A FINAL POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
berat 30kg masih diangkat manual SWH karena di SWH sudah memakai REC EIVING SETTIN G
1 2
POLYBOX DRIVER & FORK LIFT
10000
13770 15638 16178 16015 14280 15141 15517
11116 13080
5000 9764 10196 9937 9837 10087
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
RECEIVING TRIMM 1 TRIMM 2 FINAL FRAME 1 FRAME 2 S/A FINAL 1S/A FINAL 2POLYBOX 1POLYBOX 2 DRIVER 1 DRIVER 2 F/L 1 F/L 2
RECEIVING SETTING POLYBOX DRIVER & FORKLIFT
YAMAZUMI MP SMALL PART MDW (Achievement) Loading Time W/H Mp Ideal MP Act Eff