KPI 2015

(1 Year)
Achievement Achievement Achievement Target
2013 2014 2015 2015

Claim : 2,1 ppm 2,6 ppm ............ 2,0 ppm

Rejection : 0,76 % 0,56 % ............ 0,50 %

Productivity
Man Power 1118 1036 ............ 953
Forging 62,9 UMH 67,6 UMH ............ 78 UMH
Non Forging 35,3 UMH 44 UMH ............ 53 UMH

Delivery
Achiement Rate 98,7% 99,8% ........... 100%
Service Rate 91,4% 97,0% ........... 98,5%
 QA – STRATEGIC PLAN 2015
Target
Scope of Works Internal
Deffect
Customer
1 Claim
3
5 4
PRODUCTION PROCESS
2 A
SUPPLIER F E D C B CUSTOMER

FINAL
INCOMING INSPECTION PDI DELIVERY
CHECK QC PATROL BIQ F
INCOMNG
CHECK

4
SUBCONT

ACTIVITY TARGET TIME SCHEDULE

1 SETUP PDI - Pre Delivery Inspection

-Customer Satisfaction
Jan - Apr
- Eliminate claim product (no outflow)
2 Increase Quality Gate Effectiveness
- Reduce outflow from line
Apr - Jul
- Reduce PDI Activity (100% check)
3 Re-setup Quality Patrol (4 M)
- Reduce line rejection Jul - Dec
Measurement Readiness
4 Re-setup Incoming Inspection - No deffect parts outflow to prod. line Apr – Aug

5 Vendor Development - No defect part be delivered to MTM Start from Oct

PDI CURRENT CONDITION Pre Delivery Inspection
QA CHECKING FLOW
Area Check
Pengecekan dilakukan
diarea shipping preparation

SAMPLING Delivery
Store Handling FINAL CHECK
WH. FG Preparation Shipping
Area Area
OK Check NG
all stock

NG

SCRAP
Qulaity Point Check
KONDISI AKTUAL - Packaging (tag, box, stamp)
- Quality part (rust, mixing)
1. Mapping produk Belum ada mapping part kritis
2. Quality Point Visualisasi Quality point belum jelas
3. Lay_out Proses check Final pada area preparation
4. Man Power Skill Kapabilitas Man power masih rendah
5. Part Flow Flow produk belum jelas
6. Daily monitoring Monitoring belum dilakukan secara harian
7. Ergonomi Posisi pengecekan tidak terstandarisasi
 IMPROVEMENT
Concept Pre Delivery Inspection
 Process Flow

OK

Handling PDI Delivery

CHECK Shipping Area
Store Preparation TOTAL : 32 PARTS
WH. FG Area
OK Check NG
all stock

NG

SCRAP

IMPROVEMENT LAY-OUT PDI & Q-POINT

1. Mapping produk Mapping part kritis ‘32 item Part’

2. Quality Point Revisi format Visualisasi Quality point
3. Lay_out Set-up Area Pre Delivery Inspection
4. Man Power Skill Training Inspector Final Inspection.
5. Part Flow Set-up Quality Flow produk.
6. Daily monitoring Visualisasi daily monitoring
7. Ergonomi Standarisasi proses check QUALITY FLOW PRODUK
 IMPROVEMENT
Concept Pre Delivery Inspection

Before After
Inspector melakukan Member PDI melakukan
pengecekan produk pengecekan 100% for
yang berada di area 32 item part
shipping sebelum di
delivery

Handling
RESULT : Pre Delivery Inspection

1000
3,0
CUSTOMER CLAIM
PDI FINDING
800 2,5
Reduce 30 % 2,0
2,0
600 NG dimention
1,5
2,6
pcs

( bukan item check PDI )

400 1,0 0,7
Start Jan’15

768
605 0,5 0,3
200
320 0,0
2014 2015 JAN FEB MAR APR MEI JUN
0 0
Jan Feb Mar Apr Mei Jun Claim (pcs) Acc. Claim (ppm) Target

Customer Claim menurun ( 0,3 ppm / April 2015 ), Namun temuan defect part area PDI masih tinggi.
 QA – STRATEGIC PLAN 2015
Target
Scope of Works Internal
Deffect
Customer
1 Claim
3
5 4
PRODUCTION PROCESS 2 A
SUPPLIER F E D C B CUSTOMER

FINAL
INCOMING INSPECTION PDI DELIVERY
QC PATROL BIQ
CHECK F
INCOMNG
CHECK

4
SUBCONT

ACTIVITY TARGET TIME SCHEDULE

1 SETUP PDI - Pre Delivery Inspection

-Customer Satisfaction
Jan - Apr
- Eliminate claim product (no outflow)
2 Increase Quality Gate Effectiveness
- Reduce outflow from line
Apr - Jul
- Reduce PDI Activity (100% check)
3 Re-setup Quality Patrol (4 M)
- Reduce line rejection Jul - Dec
Measurement Readiness
4 Re-setup Incoming Inspection - No deffect parts outflow to prod. line Apr – Aug

5 Vendor Development - No defect part be delivered to MTM Start from Oct

QUALITY GATE CURRENT CONDITION Increase Quality Gate Effectiveness

IN-LINE QUALITY GATE (BIQ)

Point Check
- Appearance
- Dimention

QUALITY
OPERATION OPERATION OPERATION Handling
GATE
Store
NG WH. FG
-Repair
SCRAP -Rework

KONDISI AKTUAL
1. Mapping pic Quality Gate Belum ada mapping patern position pic Q. gate
2. Quality Point Visualisasi Quality point belum jelas
3. Area Kerja Belum ada concern record check sheet
4. Man Power Skill Kapabilitas Man power masih rendah
5. Part Flow Flow produk belum jelas
6. Daily monitoring Monitoring belum dilakukan secara harian
7. Review periodic Belum ada schedule review achievement Q. gate
Improvement Step : Level up Quality Awarness

Before Improve
Improve ① Improve ② Improve ③

BIQ F. Ins Claim BIQ PDI Claim BIQ PDI Claim BIQ PDI Claim

Outflow dari Production Line

①
Develop pre Delivery ② Reduce defect outflow ③ Reduce Rejection
Inspection masih tinggi Inspection Quality Gate (BIQ)  as target 2015
fungsi dari visual
inspection belum maksimal

Improvement Tool’s  4G :
Good Standardizedwork Q-point yang mudah dipahami

Good Working Condition Hardware yang memadahi

Good Follow up
Control achievement

Good Communication Periodical feed back

 IMPROVEMENT
Concept Increase Quality Gate Effectiveness

 Process Flow

QUALITY
OPERATION OPERATION OPERATION Handling
GATE
Store WH. FG TOTAL : 27 LINE, 77 INSPECTOR
NG -Repair
SCRAP -Rework

IMPROVEMENT

1. Mapping pic Q. Gate Penentuan Area Gate dan Pic Inspector. CONCERN RECORD CHECK SHEET
2. Quality Point Revisi format Visualisasi Quality point.
3. Area Kerja Pembuatan concern record check sheet
4. Man Power Skill Training Inspector Q. Gate Inspection.
5. Part Flow Flow produk belum jelas
6. Daily monitoring Visualisasi daily monitoring
7. Review periodic Pembuatan schedule review Quality Gate

TOMBOL QUALITY PASSED

 IMPROVEMENT
Concept Increase Quality Gate Effectiveness
Schedule
Kick off

Komitmen

Implementasi

Review

Before After
Standarisasi
RESULT : Increase Quality Gate Effectiveness

Cust Claim / Juni ‘15

0,3 ppm

REJECTION PDI FINDING

1000
New Part
800 0

0
pcs 600
285
400 768 Henkaten
605 135
200 Mat’l
320 74
201
122
0
Feb Mar Apr Mei Jun

Customer Claim menurun ( 0,3 ppm / Juni 2015 ), Temuan PDI menurun, Namun Internal Rejection Masih Over
dari standard.
 NEXT ACTIVITY
Target
Scope of Works Internal
Deffect
Customer
1 Claim
3
5 4
PRODUCTION PROCESS 2 A
SUPPLIER F E D C B CUSTOMER

FINAL
INCOMING INSPECTION PDI DELIVERY
QC PATROL BIQ
CHECK F
INCOMNG
CHECK

4
SUBCONT

ACTIVITY TARGET TIME SCHEDULE

1 SETUP PDI - Pre Delivery Inspection

-Customer Satisfaction
Jan - Apr
- Eliminate claim product (no outflow)
2 Increase Quality Gate Effectiveness
- Reduce outflow from line
Apr - Jul
- Reduce PDI Activity (100% check)
3 Re-setup Quality Patrol (4 M)
- Reduce line rejection Jul - Dec
Measurement Readiness
4 Re-setup Incoming Inspection - No deffect parts outflow to prod. line Apr – Aug

5 Vendor Development - No defect part be delivered to MTM Start from Oct

KPI 2015
(1 Year)
Achievement Achievement Achievement Target
2013 2014 2015 2015

Claim : 2,1 ppm 2,6 ppm 0,3 ppm 2,0 ppm

Rejection : 0,76 % 0,56 % 0,58% 0,50 %

Productivity
Man Power 1118 1036 ............ 953
Forging 62,9 UMH 67,6 UMH ............ 78 UMH
Non Forging 35,3 UMH 44 UMH ............ 53 UMH

Delivery
Achiement Rate 98,7% 99,8% ............ 100%
Service Rate 91,4% 97,0% ............ 98,5%