GEMBA MANAGEMENT Quality Control Circle Policy Management Suggestion

GEMBA MANAGEMENT Quality Control Circle Policy Management Suggestion System Standardization & Quality Assurance Cross. Functional Management Daily Management 5 S 1/15

Gemba Management in Company Management TOP MANAGEMENT MIDDLE MANAGEMENT SUPERVISOR FOREMAN & OPERATOR on i t a ) N E Z ov n In I A K t( en em ov r p e h t t rr u c t n e m ) s e l u rk o p o u m w i in t d ne n n o i a t C u in o a t GKM (R n i a em 3 S M t s 5 R sy Im 2/15

5 R IMPLEMENTATION WAY TO DEVELOP WORLD CLASS COMPANY CULTURE 5 S 5 C 5 R 5 P Seiri Clear-out Ringkas Pemilahan Seiton Classify Rapi Penataan Seiso Cleaning Resik Pembersihan Seiketsu Conformity Rawat Pemantapan Shitsuke Custom Rajin Pembiasaan 3/15

5 R 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 5 R 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 TRAINING Attitude Behavior Workplace 5 R IMPLEMENTATION Culture Attitude Customs Behavior Workplace ( 3 principles : Consistency, Continuity & Simplicity) 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)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 8/15

SS IN TOYOTA MOTOR CORP. (1984) • • Number of suggestion : 2. 1 million Number of suggestion/ employee : Participation level: 95% Acceptance level: 95% 40 9/15

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 10/15

THE DIFFERENCE OF SS WEST VERSION AND JAPAN VERSION West (America) Japan • Emphasize on economical output( great ideas) • Emphasize on participation (small ideas) • Extremely put emphasis on Financial incentive • Psychological Incentive (pengakuan dan aktualisasi diri) • Personal motivation and group • SS Committee responsibility • 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 • System • Organization • Regulation Mechanism • Reward System • Standard Evaluation Suggestio n • Suggestion Form system 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