12/16/2009

Part 1: Waste, Enemies You Must

Know

Fathurohman

1. Steps toward mature process.

2. An analogy for learning: from fighting fire to
innovation.
3. Characteristic comparison: responsive vs.
measured-planned system.
4. Eight wastes in floor: problems like fire.
5. Conclusion.

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(2) EARLY SYSTEMATIC

(1) REACTING TO PROBLEMS APPROACHES

Strategic and Strategic and

Operational Goals Operational Goals

Operations are characteristics by activities rather than by processes, The organization is at the beginning stages of conducting operations by
and they are largely responsive to immediate needs or problems. processes with repeatability, evaluation, and improvement and some
Goals are poorly defined. early coordination among organizational units.
Strategy and quantitative goals are being defined.

(3) Aligned Approaches (4) Integrated Approaches

Strategic and Strategic and
Operational Goals Operational Goals

Operations are characterized by processes that are repeatable and Operations are characterized by processes that are repeatable and
regularly evaluated for improvement, with learning shared and with regularly evaluated for changes and improvement with other affected units.
coordination among organizational units. Processes address key Efficiencies across units are sought and achieved through analysis, innovation,
strategies and goals of the organization.
and the sharing of information and knowledge. Processes and measures track
programs on key strategic and operational goals.

1 2

Reacting to the problem General improvement orientations

Run with the hose and put out the fire Install more fire hoses to get to the fires quickly and reduce their impact

Systematic evaluation & improvement
Evaluate which locations are most susceptible
to fire. Install heat sensors & sprinklers in
those locations.
Learning & strategic improvements Organizational analysis & innovation
Install system wide heat sensors & Use fireproof & fire-retardant materials.
sprinkler system that is activated by the Replace combustible liquid with water
heat preceding fire based liquid. Sensors & sprinklers
become the secondary line of protection

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MEASURED-PLANNED
RESPONSIVE SYSTEM SYSTEM
1. Operations are characteristics by activities 1. Operations are characterized by processes
rather than by processes. that are repeatable and regularly evaluated
Activities: things have to be done. for changes and improvement with other
Process: connected series of actions with a affected units.
purpose in a clearly method. (Oxford dict.)

2. Largely responsive to immediate needs or 2. Efficiencies across units are sought and
problems. achieved through analysis, innovation, and
the sharing of information and knowledge.
3. Goals are poorly defined. 3. Processes and measures track progress on
key strategic and operational goals.

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Scrap or rework

Time

Overhead cost

Late delivery

LOSSES
Safety stock

Overstock

Delayed/cancelled order

Material & production cost

Space & handling cost

LOSSES
Moral

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Accident in
handling Transportation
time
Transportation
Effect

Working force Transportation

tool

Stock out

Capacity Idle
bottleneck
time
Equipment
downtime
Process delay

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Reaching
for

Contoh: Alur informasi servis

Info diterima penjualan Info diterima penjualan

Diteruskan ke transit Diteruskan ke transit

Barang diserahterimakan ke Gudang Barang diserahterimakan ke Gudang

Jadi Jadi

Gd. Jadi konfirmasi Gd. Jadi membawa barang ke line

Servis
kedatangan ke Penjualan

PPIC menjadwalkan
tindakan perbaikan
Info sampai ke Servis

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Long set up Longer lead time

Defect rate Damaged good

Excess raw
material, WIP, Delay
Late delivery
finished goods Housekeeping time
Machine trouble
Storage cost
Unbalanced work station Transportation cost

Misprediction Other hidden

problems

Ideas
Learning
opportunities

Skills

Improvements

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1. Wastes are in many manufacturing processes that add

cost without adding to value.
2. Waste have marked up the operational cost and became
a dangerous potential to burn out business.
3. Focus on eliminating waste is the ultimate goal of
kaizen, the process of making continuous and
incremental improvement.
4. The spirit of kaizen just live in a measured-planned
management system. It won’t work in a sporadic-
responsive system.