Modul 5R

1
GEMBA MANAGEMENT

Policy Management
Quality Control Circle
Suggestion System
Standardization Quality Assurance
Cross- Functional Management
Daily Management
5 S
2
Gemba Management in Company Management
TOP MANAGEMENT
Innovation
Continuous Improvement (KAIZEN)
MIDDLE MANAGEMENT
Maintain and implement the current system
(Routine work)
SUPERVISOR
GKM 3S 5R
FOREMAN OPERATOR
3
5R IMPLEMENTATIONWAY TO DEVELOP WORLD CLASS
COMPANY CULTURE
5R Ringkas Rapi Resik Rawat Rajin
5P Pemilahan Penataan Pembersihan Pemantapan Pembi
asaan
5S Seiri Seiton Seiso Seiketsu Shitsuke
5C Clear-out Classify Cleaning Conformity Custom
4
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

5
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

6
TRANSFORMATION BEHAVIOR WORKPLACE CONDITION
TRAINING
Workplace
Behavior
Attitude
5R IMPLEMENTATION
Workplace
Behavior
Attitude
Culture
Customs
( 3 principles Consistency, Continuity
Simplicity)
7
SUGGESTION SYSTEM Definition

• Management system that involves every customer
  in improving quality through individual
  suggestion for improvement

8
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

9
SS IN TOYOTA MOTOR CORP. (1984)

• Number of suggestion 2.1 million
• Number of suggestion/ employee 40
• Participation level 95
• Acceptance level 95

10
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

11
THE DIFFERENCE OF SS WEST VERSION AND JAPAN
VERSION

• West (America)
• Emphasize on economical output( great ideas)
• Extremely put emphasis on Financial incentive
• Personal motivation
• SS Committee responsibility

• Japan
• Emphasize on participation (small ideas)
• Psychological Incentive (pengakuan dan
  aktualisasi diri)
• Personal motivation and group
• Top management responsibility

12
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

13
SS IMPLEMENTATION STRATEGY AND MECHANISM

• System
• Organization
• Regulation
• Reward System
• Standard Evaluation
• Suggestion Form

Mechanism
Suggestion system
Strategy

• Education and Training
• Campaign
• Promotion activity
• Motivation encouragement
• Coaching and Counseling

14
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

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