SMALL GROUP ACTIVITY

1. SMALL GROUP ACTIVITY PT.Sinyotama Industri P. Rod BRAVO Topic : Reduce Scrap Over Sanding From Rp. 1,913,344 to Rp. 451,182 Period February - April 2008

2. STRUCTURE OF ORGANIZATION Members : Motto : Together For A Success

3. Step 1 DEFINE

4. PROBLEM DEFINITION PARETO DIAGRAM LAST 3 MONTH DATA Focus Improvement

5. PROBLEM DEFINITION Sample Over Sanding • Over Sanding is : • This Nc has because blank stoped on sanding process with sanding belt. • Effect: • Hight Scrap • Many additional to M.Rod • Shipment delay

6. Step 2 MEASUREMENT

7. BACKGROUND (LATAR BELAKANG) 1. LAST THREE MONTHS DATA • The disadvantage of problem to production result. • SOT Not Achieve. • Customer wos not satisfied. • Many hidden factory.

8. BACKGROUND (LATAR BELAKANG) 2. TARGET ACHIEVEMENT Achive plan Target is : 100% 58% Rp. 451,182 42% This setting Target with agree by our Manager : Mr.Chinpen

9. BACKGROUND (LATAR BELAKANG) SCHEDULE ACTIVITY This is our schedule activity has effective

10. Step 3 ANALYZE

11. IDENTIFY & VERIFICATION OF PROBABLE COUSES Man Material Lazy Likes Sending No check 6. Nothing QC Incoming 5. Nothing Standard sending Why Scrap Over Sending? Blank Incoming Quality No good Easy shaky 7. Easy broken off Pushed is strong Sending/buffing Belt 11. Key lock not pass 10. Tier is stoped Seater blank 9. Sending is shaky 8. Use cutter of cut Tier Setting belt no stndard 12. Setting No fix Often leak Easy moved Use lakban Method Machine Base on braistorming with fishbone chart, we have 12 possibility root couse.

12. IDENTIFY & VERIFICATION OF PROBABLE COUSES 1. C & E MATRIX DIAGRAM Proses inputs

13. IDENTIFY & VERIFICATION OF PROBABLE COUSES 2. C & E MATRIX DIAGRAM Proses inputs After make analyze with C & E Matrix we found five root problem to cause over sanding , material very high until three month ago.

14. IDENTIFY & VERIFICATION OF PROBABLE COUSES 3. Proportion root cause by Pie Chart

15. IDENTIFY & VERIFICATION OF PROBABLE COUSES 4. ROOT CAUSES 4.1. No Follow Work Instruction 4.2. To less responsibility ~NIL~ • Problem Faced : • Never audit by leader • Knowledge no enough • Many Scrap • Problem Faced : • Lazy to checking • Work to less focus • Many Scrap

16. IDENTIFY & VERIFICATION OF PROBABLE COUSES 4. ROOT CAUSES 4.4. Key Lock Not Pass 4.3. Setting No Fix ~NIL~ • Problem Faced : • Loose time for setting • Landscape is shaky • Tier is shaky • Effect Scrap • Problem Faced : • Loose time for setting • The use base of blank is shaky • Tier is stoped • Effect Scrap

17. IDENTIFY & VERIFICATION OF PROBABLE COUSES 4. ROOT CAUSES 4.5. Sending is shaky • Problem Faced : • Blank Wave • Blank of pinshed • Effect Scrap

18. Step 4 IMPROVE

19. RECOMMENDE SOLUTION TREE DIAGRAM Topic REDUCE SCRAP OVER SENDING We choose alternative with high score as good solution into root problem finished.

20. RECOMMENDE SOLUTION TREE DIAGRAM This is a comparison between root problem with our alternative to taken for definite indeed our solution very effective for finished this problem

21. IMPLEMENTATION 4. Activity Program This is a implementation we makes with accept times & schedule

22. IMPLEMENTATION 4. ACTION 1. Made a Place Drawing & WI Before SGA After SGA ~NIL~ • Problem Faced : • Difficult to knowledge • Knowledge no enough • Many Scrap • Advantage: • Easy Manpower for understand • Increase knowledge manpower • Reduce over sending

23. IMPLEMENTATION 4. ACTION 2. Focus with jobs Before SGA After SGA ~NIL~ • Problem Faced : • Lazy to checking • Work to less focus • Many Scrap • Advantage: • Easy manpower for know • Update for skill

24. IMPLEMENTATION 4. ACTION 3. Maintanance made monitoring Check list Before SGA After SGA ~NIL~ • Problem Faced : • Never audit • Long time for order repair • Advantage: • Easy Manpower for monitoring • Increase quickly for repair.

25. IMPLEMENTATION 4. ACTION 4. Modifikation by maintanance Before SGA After SGA • Problem Faced : • Loose time for setting • Used a key lock “L” for setting • Tier is stoped • Effect Scrap • Advantage: • Easy Manpower for setting • Increase knowledge manpower • Reduce over sending

26. IMPLEMENTATION 4. ACTION 5. Made lakban back sanding belt Before SGA After SGA • Problem Faced : • Lazy to checking • Work to less focus • Many Scrap • Advantage: • Easy Manpower for setting • Increase knowledge manpower • Reduce over sanding

27. RESULT 5. Weekly Result 47109 

28. RESULT 5. Comparetion Before SGA During SGA

29. Step 5 CONTROL

30. STANDARIZATION 1. Standarrization Form

31. FOLLOW UP 2. Standarrization Form Monitoring 1). Form Monitoring Scrap 2). Made check list machine There are two form monitoring at follow up, during that after SGA

32. COST SAVING This is Cost saving we got reduce with average three month is Rp.1,806,385 Has active of SGA

33. 4.1.TANGIBLE BENEFIT • Reduce Scrap Over sanding from • Rp1,913,344 to Rp1,311,216 • To less DLNC from 3 % to 2% • Cost Saving / three month Rp.1,806,385.- 4.2. INTANGIBLE BENEFIT • Made good level to take notice official about over sanding • Made good level for teamwork between member Under Coat • Made good level for education in makes data analyze • Made good level for skill in to operational computer • Made good level to made report and percentage

34. NEXT PROJECT REDUCE LINE NC BROKEN

35. END PRESENTATION THANK YOU SEE YOU NEXT SGA