WEBINAR

Lean Manufacturing System dan

Perkembangan Teknologi Terbaru

Ir. I Made Dana M. Tangkas, M. Si., IPU, ASEAN Eng.

Presiden Institut Otomotif Indonesia (IOI), Founder & CEO IBIMA
SEA/Director Indpdt/Member of BOD Mtng of PT Toyota Motor Indonesia
Chairman BKTI PII, Chairman Komite Tetap ILMAT KADIN

Universitas Medan Area

Selasa, 16 Juni 2020
Contents:
1. Kondisi Bisnis & Industri dan Perkembangan Teknologi
Industri 4.0 Menuju New Normal.
2. Lean Manufacturing/Enterprise: Value, System &
Leadership (Toyota
Way, TPS, Leaders)
3. Tantangan & Peluang Industri 4.0

2
 1. KONDISI BISNIS & INDUSTRI DAN INDUSTRI 4.0
MENUJU NEW NORMAL
WORLD MAP (Potentiality of Domestic & Global Market)

North America EEC

Asia
NAFTA APEC
Europe

AFTA+3
GCC
APEC Africa
AFTA
COMESA Indonesia
South America
INDONESIA
MERCUSOR
Australia

Page 4 From Indonesia for Global Market

 Sumber : https://covid19.go.id/

Sumber :
https://www.kompas.com/covi
d-19
 INOVASI UNTUK MENUJU INDUSTRI BERDIKARI & SEJAHTERA 2030

2015 2025 2035 2045 COMPETITIVENESS

Per capita 2000 2005 2010
2045 Innovation and
$44.500-
49.000 sophistication factors
Prediksidan target
HIGH peningkatan 30%
INCOME income/kapita
2030
Innovation- 50% 20%
Russiastage $ 13.000
driven
$14.250- Spain $ 31.990
16.500 INNOVATION DRIVEN:
• Business sophistication South Korea $ 22.420
• R&D Innovation Taiwan $ 19.980
$12.616
UPPER Efficiency
Brazil enhancers
$ 12.590
China $ 5.450
MIDDLE Malaysia $ 9.980
INCOME Sulit beranjak Mexico $ 10.050
meningkatkan South Africa $ 8.070
income /kapita Thailand $ 4.970
$4.086 10 50% 40%
2012 EFFICIENCY DRIVEN:
%
India Efficiency-
$ 1.510
$ 3.592 driven$stage
Indonesia 3.592
LOWER • Higher education and training
• Goods market efficiency Philipines $ 2.470
MIDDLE 2010 • Labor market efficiency Vietnam $ 1.400
INCOME $ 2.500 • Financial market development
2005 • Technological readiness
$1.036 $ 1.203 • Market size

LOW
INCOME
FACTOR DRIVEN: 5 Basic recuirement
• Institutions % 35%
• Infrastructure
2000
$ 657 • Macroeconomic environment 60%
• Health and Primary education Factor-driven stage
Sumber: Economist Pocket World in Figures, WEF-GCR + prediction
 Trend Adaptasi terhadap Perubahan yang Terjadi
Pasca Wabah Covid-19 di Sektor Industri

Diversifikasi Inovasi Teknologi

Produk & Servis Produk, Servis & Proses

TREND ADAPTASI

E-Commerce
Pemberdayaan (Online Business &
Local Resources Semi Offline)
(SDA & SDM)
Productivity & Efficiency
(Managing Demand & Supply)
 Perubahan Perilaku setelah “New Normal”

• Dengan adanya Covid-19, maka akan berdampak terhadap perilaku kehidupan yang
mengakibatkan perubahan perilaku pasar dan perilaku industri setelah “New Normal”

Perubahan Perilaku Perubahan Pola

Perubahan Pasar
Kehidupan Industri

-Menggunakan media -Belanja Online, eCommerce -Efisiensi & produktivitas

virtual/Digital dlm Bekerja,
Meeting, bersosialisasi dll
-Work From Home / Stay
@Home
-Menghindari Kerumunan
-dsb
-Mengurangi Makan di Restoran
menjadi food delivery
-Platform Digital & Media Sosial
akan tumbuh pesat
-Belanja kebutuhan dasar :
Makan, Kesehatan, dll
-dsb
-Otomasi Produksi
-Menggunakan Teknologi
Virtual/Artificial Inteligent
-Diversifikasi & inovasi produk,
proses & servis serta supply chain
(Menaruh telur investasi di
beberapa keranjang)
-Penggunaan Local Resources
(SDA & SDM).
 2. LEAN MANUFACTURING/ENTERPRISE: VALUE, SYSTEM &
LEADERSHIP (TOYOTA WAY, TPS, LEADERS)
Integrated National Industrial Development System

Sistem Industri Direction : Formation Value, System,

Leadership (V-S-L)
Nasional Terpadu
Sasaran : - Roadmap Industrial Development
- Increased industry contribution
to GDP
Supply Chain Management
Value Chain Management (Value added)

Secondary Industry
Primary Tertiary
Hulu Antara Hilir
Industry Customer
Industry

- Oil & Gas & Coal Domestic

- Metals & Minerals Down Stream Market
Overseas Market
Upstream Intermediate
- Agro, Maritime & Industry (Export)
Industry Industry
Water, air, etc.

Aplikasi dalam Pengembangan Industri Terpadu

 Rules of the Game in Developing Industry (Always
Changing every time and keep lean concept in the journey)
Perubahan dari : craftmenship ke mass production dan ke lean production
Future
High volume dan banyak varian Industrytoday: Scale/Scope
Multi purpose mc, Multi function workers Globalization

Pull system , material is first Lean Production Japan Price/Quality

Europe Technology
VW/bmw/Mercedes
Toyota/HondaEconomy/Sportiness
Differentiation Differentiation
GM Decentralization (sloan)
Single purpose mc
Internal Expansion
High volume, Push system
Mass production
Ford Taylorism Varian produk terbatas
Perlu skill tinggi, Volume sedikit Specific job unt operator
Craftsmenship general purpose mc Mesin is first Oil Crisis

1890 1910 1930 1950 1970 1983 1990 2000 2010

Source : Proton

2 Options, Manufacturing Industry Facing IR 4.0

4thA graceless degradation or a revolution
The 4th
Customer revolution Unbundled
value
Toyota’sleap Lean
A 4th revolution :
Sloan’s leap
▪ apa yang akan dibuat / diproduksi Mass customized
▪ apa yang di-maui oleh customers Ford leap
▪ apa brand / produk yang dipakai
▪ apa dan bagaimana cara Craft
marketingnya
Volume
 VALUES : The “4P” Model of
Toyota Way

PROBLEMThe ToyotaWay
Toyota’ s SOLVING Respect
Term (Continuous for People
Improvement & -‐Respect
Learning)
-‐Team Work
PEOPLE & PARTNERS Continuous
(Respect, challenge Improvement
and grow them) -‐Challenge
-‐Kaizen
PROCESS -‐Genchi
(Eliminate waste) Genbutsu

PHILOSOPHY
(Long-Term Thinking)

Page 14
 Business Activity (SYSTEM) : Lead Lime for a Company
Business/ ProductPlan

Simultaneous
Design Engineering

Procure equipment
& Tools
Investment
Production Plan

Collect
Production money Toyota
Production
Distribution System

Sales

The key in our business is how to collect moneyquickly, to increase

Page 15
cash flow for thecompany.
 Cost Reduction is Absolute Requirement
for Increased Profit
(1) Selling price = Cost + Profit
(2) Profit = Selling Price - Costs Cost Reduction

(1) Cost +Profit (2) Cost Reduction

Profit
Profit Selling Price Selling Price
Cost Cost

Methods for Raise the selling price Demand > Supply

Reduce the costs Demand < Supply
increasing profit

Customers determine the selling price

Page 17
Productivity  Labor Productivity

Labor Productivity
(with smaller man power)
Equipment Productivity
Productivity (with smaller equipment investment)
Material Productivity
(with less costly materials and higher yield ratio)

The quality of design plays a decisive role. Still the costs vary
depending on the manufacturing method
 Cost Dependent on Production Method
Cost change depending on the production flow/method, even with
the same design, same equipment, and the same material
Component of COST

1 2 3 4
2 2 2 2
Other Raw
material 3 3 3 3
Energy purchase
1 1 1 1

Labor Part
Expense ProcessFlow
purchase

1 2 3 4
2 3 2 3
Cost in Cost caused by
Common difference in 1 4 4
1
between production method
companies
ProcessFlow
Page 19
*) Cost Reduction & GENTAN-i
 MUDA : WASTE, UNNECESSARY WORK
MURA : UNEVERNESS, UNSTABLE, FLUCTUATIVE
THINGS
MURI : OVERBURDEN, OVERLOAD, OVERWORK
CONDITION

[C]
Net Work Muda
A. MUDA : Motion no necessary for
production work
[A] B. Non-Value- Adding Work : Motion that are
O perator’s necessary but do not add any value to the
motions product at the present work stage.
C. Net Work : Motion that add values to the
product
Non-Value- Work
adding work
[B]
 Summary of TOYOTA Production System

J.I.T
Realization embodying
“Customer First”
discipline Timely

Providing customers with

Elimination of waste
well made products at
Muda (Non-value Added) QCDSMPE
reasonable price in a Mura (Uneverness)
timely manner
Muri (Overburden)

Taking back the Well-made produc t at

investigation promptly in reasonable cost
the limited capital
resource
Standardized Work Jidoka
Page 25 Kaizen (incld. People,5R)
 Standardized Work &Standardization
Standardized Work &
COST Standardization KAIZEN
Safety, Quality (4M : Material, Machine, Man
Environment and Method)

In Safety
In Quality
Productivity In
Productivity

COST REDUCTION
LEADERSHIP :
MAKING PEOPLE before MAKINGPRODUCT
3. Tantangan & Peluang Industri 4.0
End of Beginning of Beginning of
18th century 20th century the seventies Today

6 Keys for IR4.0 & New Normal (Progressive & Distruptive) :

1. Democratization (3D printing, Drone, etc)
2. Digitalization (Wearable (AR/VR), Holography, IoT connectivity)
3. Disintermediation (Advanced Robotic, Big/large data lakes, etc)
4. Demonetization (Platformization, Life as Services)
5. Decentralization (Internet of Value: Blockchain & DLT, from Manopoles/oligarchies to nades, etc)
6. Dematerialization (Fintech, ePayment, currency notes to bits & bytes)
 From Lean Production (IR2.0) to Lean Manufacturing (IR3.0)
and then to Lean Enterprise (IR4.0)
(One global operation – change corporate culture – change to new business model –
collaboration)
Innovation Strategy
Objectives
World Class Enterprise
4S (Speed – Slim – Simple – Smart)
Time Line & 2.0 Lean Production 3.0 Lean Manufacturing 4.0 Lean Enterprise
Theme
Customer &
Purpose Cost Reduction Lead Time
product Lifecycle

Basic Plant Management Supply Chain Management On demand Type Business

Management
Model (SCM & CRM)

Focus production System Integration Manage All Aspect

Scope Domestic & Regional Regional Global

Tipping points : Future digital and hyper connected world …. Will have occurred by 2025 !!!
world economic forum identified in sepember 2015 : 21 tipping points ; 800 executives and experts from
the information and communications; Technology sector participated
Drivers : megatrends & new normal
Physical : autonomous vehicles , 3D printing , advance robotic , new materials
Digital : internet of things (IOT) , RFID , block chain , bitcoin , digital platforms , Artificial Intellegence (AI) , big data
Biological : syntetic biology , health care 21
 SCHEME OF FUTURE IMPLEMENTATION OF INDUSTRY 4.0
INTEGRATED INDUSTRY
INFORMATION SYSTEM (IIIS)
CYBER . Give sense to complexity
BIGDATA . Creativity
SECURITY CLOUD
. Collaboration Manufacturing
COMPUTING . Customer & marketing
. Strong Protection
intimacy
for internet
based . Cyber Physical System (CPS) . Flexibility
. Numerical command . Perfect match with
manufacturing. ADVANCEDMANUF
SENSOR . Full automation customer’sneeds
. TechProduct
with longer
SYSTEM . Totally Interconnected system with production mass
.Zero default / . M/C to M/C communication efficiency
llife cycle
deviation . On demang
. Reactivity MANUFACTURING manufacturing
. Traceability
Suppliers .Predictability
EXECUTIONSYSTEM
Client

3D PRINTING/ NANOTECH/ADVANCED AUTONOMOUS

ROBOT Internet of
ADDITIVEMANUF MATERIALS VEHICLE Thing
LOGISTIC4.0
.Scrap elimination .Smart value added product .Real time -Autonomy .Flow optimization .Object tagging
.Mass customization .Technology differentiation Productivity .Increased security .Internet object com
. Fullyintegrated
.Rapid Prototyping .Connectivity .Full transparancy or .Lower cost .Optimized stock
supply chain.
. Interconnected system data reporting .Reduce waster
. Perfect coordination
FUTURE PLANT IOT TELEMATIC & AFTER
.Clean & Re Newable Energy
.Energy Strorage
MARKETBIGDATA
.Alternatiev RawMaterial
Source : MAI/IOI
 Management (Corporate) Actions for Shifting to IR 4.0
Toward IR 4.0 to improve “Productivity”, “Supply Chain Productivity” and “Trace Ability” to
win the competition both domestic and export

Concept of IR 4.0 Initiative for Applying IR 4.0

A
 Improve the productivity by
Productivity reducing “down time” with
Improvement adding the sensor to the
machine

B
Supply Chain  Realize efficient Supply
Network chain with the One End to
Improvement end integrated system from
customer to supplier
ENABLERS:
C
 Trace the history of defective
• Computing power, storage capacities, data analytics, Trace Ability parts quickly and make
networking ability, Improvement necessary corrective action
• Internet security & trust for collabtn and share experience

DEVELOPMENT: D
 Catch up new skill to face
Human
industry 4.0 era
• Collaborative manufacturing, shared manufacturing, Resource Dev.
strategic production network, project based
manufacturing systems, e-logistics, e-commerce
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• Compatibility, interoperability, traceability,
standardization, multi-skilled trusted worker
 Human Resources Development (Man Power) Toward IR4.0
Human resource is the most important asset for Industry, human resource need to catch up
the New Skill of IR 4.0 in addition with the mastering existing skill.

Necessary Skill for Human Resource by eachStep

Current
Industry 2.0 Industry 3.0 IR 4.0

Data Analysis
Productivity
• Basic knowledge of
Task Efficiency internet, technology
• Operation ReviewAbility
Basic Skill • Machinery Engineering • Software using skill
• Taskunderstanding • Skill of machine using, • Data readingskill
• Communication • Effective way for maintenance
• Teamwork implementingtask
• Data analyzingskill
• Discipline Compliance • Basic tool skill

Existing Skill New Skill

40
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