GEMBA MANAGEMENT

Quality Control Circle Policy Management S tandardization & Quality Assurance Cross Functional Management Daily Management Suggestion System 5 S 1/15

Gemba Management in Company Management

TOP MANAGEMENT MIDDLE MANAGEMENT SUPERVISOR FOREMAN & OPERATOR GKM 3S 5R 2/15

5S S eiri

5R IMPLEMENTATION

WAY TO DEVELOP WORLD CLASS COMPANY CULTURE S eiton S eiso S eiketsu S hitsuke 5C C lear-out C lassify C leaning C onformity C ustom 5R R ingkas R api R esik R awat R ajin 5P P emilahan P enataan P embersihan P emantapan P embiasaan 3/15

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 4/15

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 5/15

TRANSFORMATION:

BEHAVIOR & WORKPLACE CONDITION

Attitude TRAINING Behavior Workplace 5R IMPLEMENTATION Culture Attitude Customs Behavior ( 3 principles : Consistency, Continuity & Simplicity) Workplace 6/15

SUGGESTION SYSTEM Definition

Management system that involves every customer in improving quality through individual suggestion for improvement 7/15

SS DEVELOPMENT IN JAPAN (1984)

• THE BIG TEN GROUP IN SS IMPLEMENTATION • Matsushita (Panasonic) • Hitachi • Mazda • Toyota • Nippondenso • Mitsubishi Motors • Nissan Motor • Aisin Seiki • Bridgestone Tire 6.58 million 4.65 million 3.06 million 2.15 million 1.43 million 1.12 million 1.07 million 0.97 million 0.95 million • Japan National Railway 0.78 million 8/15

SS IN TOYOTA MOTOR CORP.

(1984)

• Number of suggestion : 2.1 million • Number of suggestion/ employee : 40 • Participation level: • Acceptance level: 95% 95% 9/15

COMPARATIVE STUDY ON SS DEVELOPMENT IN AMERICA AND JAPAN (1989) USA Japan Number of people implementing SS 282 Number of employee involved 8.642.269

666 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 Adoption rate Rerata award/adoption Rerata economy/adoption Economy/ 100 employee 9 32% $602.15

$6.114

$22.825

75 87% $2.20

$110 $365.656

10/15

THE DIFFERENCE OF SS WEST VERSION AND JAPAN VERSION

West (America)

•Emphasize on economical output( great ideas)

Japan

•Emphasize on participation (small ideas) •Extremely put emphasis on Financial incentive •Personal motivation •SS Committee responsibility •Psychological Incentive (pengakuan dan aktualisasi diri) •Personal motivation and group •Top management responsibility

11/15

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 12/15

SS IMPLEMENTATION STRATEGY AND MECHANISM

Suggestio n system Mechanism •System •Organization •Regulation •Reward System •Standard Evaluation •Suggestion Form Strategy •Education and Training •Campaign •Promotion activity •Motivation encouragement •Coaching and Counseling

13/15

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 14/15

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 15/15