SMART

FACTORY
Solusi Menghadapi Pandemi

Jakarta, 28 September 2021

PROFILE MODERATOR

Rizky Abdillah Ramadhan

➢ Kaizen & Project Improvement
PT. Gunanusa Eramandiri

➢ Penulis Buku
Kaizen – Small Steps for Big Dreams

➢ Buku ini sudah bisa dipesan di Tokopedia, dengan mengklik link

berikut : https://www.tokopedia.com/adabooks
PROFILE NARASUMBER

Ringgo Novianto
➢ Tim Perumus SKKNI Lean Manufacturing, Kemenperin RI 2020

➢ Toyota Production System Master Trainer (2018 – sekarang)

➢ Membimbing 6 National Trainer yang mendevelop 30+

perusahaan tier-2
PROFILE NARASUMBER

Rofik Dhatomo
➢ Tim Perumus SKKNI Lean Manufacturing, Kemenperin RI
2020

➢ Toyota Production System Master Trainer (2018 – sekarang)

➢ Membimbing 9 National Trainer yang mendevelop 30+

perusahaan tier-2
SMART LOGISTIC
Smart Logistic
 Content
• Pandemic Condition
• Industrial Challenge
• Industry operation problem
• Strategy to face pandemic
• Lean Process Flow
• Smart Factory is the solution
• Type of Production System
• Smart Logistic
 Pandemic Condition
• Progress of Positive Confirmed Cases of Covid-19 (National)
60.000
https://covid19.go.id/peta-sebaran

50.000
Covid-19 patient in Industrial sector down
Hospital full of hospital parking
40.000
Covid-19 patients
Perlahan, Industri Otomotif
30.000 Mulai Bangkit Berkat PPnBM
https://www.suara.com/otomotif/2021/08/19
/175623/perlahan-industri-otomotif-mulai-
20.000
bangkit-berkat-ppnbm

10.000

0
2 Mar Apr Jul Oct Jan ‘21 Apr Jul 24 Sep
 8 Industrial Challenge at Pandemic
1. contract and payment delays. Keep PROFIT
2. increase in the price of raw and supporting
materials.
3. exchange rate fluctuations.
4. implementation of health protocols and
social distancing makes production utilities
go down.
5. reduction of labor.
6. logistics transportation difficulties. Business
Development
7. increase in shipping costs.
8. operational restrictions in local regulations.
industry must continue
https://www.cnnindonesia.com/ekonomi/20200925142007-
the operation to achieve Payroll
92-550939/kemenperin-ungkap-8-tantangan-industri-di-
tengah-corona productivity targets
Industry operation problem
Wastes (MUDA) ❼

Waste or often called ❶

Defect &
❻ Waiting repair
Muda in Japanese is
an activity that
7
Motion
Over
absorbs or wastes MUDA
(Wastes)
production
❷
resources such as Inventory
Over
Process
spending additional ❺ Build
time or costs but Conveyance

does not add any “MUDA”

❸
value to the activity. ❹ awareness
 Industry operation problem
• So many items to be made and the assembled components have the
potential to cause misprocessing.
Ballpoint assembly process No component
can be
changed so
that it
becomes a
faulty
assembly is a
wasted
reject

Mistaking
components is
a wasted
motion…
 Industry operation problem
• A lot of time is wasted due to the process of changing product types due to
the difficulty of finding materials and tools.
Difficult to remember the job
sequence with many items

It's not easy to

picking up the
materials needed

which one to take

first and next?

Difficult to find the position of material
placement without clear instructions
No one should take a long time to find the location of the
placement of materials and goods, that is a wasted convey
How to make
it all easy…?
There should be no eyes for a long time to find the location
of the component placement, that is a wasted motion
 Industry operation problem
• There are materials that are less than the minimum standard and that are
more than the maximum standard

It is difficult to update the actual stock condition (in and out)

and do stock taking
Material that exceeds the maximum limit is a waste inventory
Stock taking takes a long time, that is a wasted process
Strategy to face pandemic
The competitiveness of a company depends on value
industry must still operate by adding in the production process
implementing strategy Value adding is what the customer is willing to pay for !

Minimizing labor Value adding is diminished by losses (e.g. scrap)

and waste (e.g. unnecessary transportation)
and restrictions
human interaction

Very important to eliminate

wastes in manufacturing process
by KAIZEN activity
 Lean Flow Process (No MUDA)
Logistics systems have
a strategic role in
creating lean processes

How to flow the

material according to
the demand for the next
A lean process is a process that flows smoothly including the process, the right type,
flow of materials and information, so that it can produce the amount needed and
products in a relatively short lead time. when it is needed
 Smart Factory is the solution
• Technology assistance is needed to reduce
human interaction
• Need an application
that can help human
work without
thinking for a long
time
• Need tools to do
simple work that has
no added value
Type of Production system
Production system can be classified
into Full-Automation, Semi-
Q (Volume of Productions)

Automation, and Manual depending

on the number of models and
production volume.
Smart Logistic (automation operating system)
Drone

Robotic Arm
AGV

Smart warehouse
management system.
Worker hands holding
tablet to control.

Reduce human interaction, easy to picking up the materials needed, real time stock update,
eliminate motion that has no value added with assistive devices, reduced wasted convey
Smart Logistic (easy human operation)

Easy operation & error

proofing with Pick to Light
System (PLS)

The work is done easily and more practically, paperless, can prevent the mistaking or wrong assembly
without having to think a long. Implemented kanban system to keep standard stock, no wasted motion
STRENGTHEN TPM
as
BASIC for SMART
MAINTENANCE

Rofik D. 2021
 APA ITU TPM

• TPM dikembangkan untuk menunjang perkembangan TPS. JIPM ( Japan Institute of Plant Maintenance ) saat
melakukan Audit PM di Nippon Denso pada 1970-an. (Ross Kenedy :2019)
• Anda tidak dapat menerapkan Lean Manufacturing jika tidak memiliki line / mesin yang bisa diandalkan.

TPM = Total Productive Maintenance

1950 1960 1970 1980 1990

Breakdown maintenance

Preventive maintenance

Corrective maintenance

Total productive maintenance

PENJELASAN 8 PILAR

1 2 3 4
Edukasi dan Pelatihan:
Planned Maintenance : Autonomous Maintenance
Focused improvement : Mendidik karyawan agar
fokus meningkatkan artinya adalah melakukan
melakukan perbaikan memiliki skill dan
availability dari mesin perawatan terhadap
yang berkelanjutan menguasai teknik untuk
dan peralatan dengan mesin yang dipakai.
walaupun sedikit demi melakukan autonomous
cara mengurangi (pengencangan baut,
sedikit maintenance
breakdown mesin. pengisian oli)
(maintenance mandiri)

5 6 Office TPM: 7 8
Quality maintenance Safety, Hygene & Early Tools Management,
bagaimana membuat
adalah pengaturan Environment (SHE): untuk meningkatkan
aktifitas kantor yang
mesin yang memperkecil adalah aktifitas untuk ketersediaan equipment
efisien dan
kemungkinan terjadi menciptakan area kerja baru dengan mengurangi
menghilangkan kerugian
cacat berulang kali. Hal yang aman dan sehat, waktu setting melalui
yang mungkin terjadi.
ini dilakukan untuk dimana potensi bahaya pengetahuan yang di
(lead time pengadaan
memastikan tercapainya di petakan dan dapat dalam penerapan
alat penunjang aktifitas
target zero defect. ditanggulangi TPM
TPM)
HUBUNGAN LEAN MANUFACTURING &
INDUSTRIAL REVOLUTION 4.0

Lean Manufacturing
(support by TPM) IR 4.0

Engine Turbocharger
Penerapan Lean manufacturing yang di support oleh penerapan TPM
Equipment 8 BIG losses OEE Element

Loading time – down time

Avilability = X 100%
Loading time

Product unit
Std
cycle Time
x processed
Performance rate = X 100%
operating time

Product unit
processed
- Defect
Quality rate = X 100%
Product unit processed

Overall Equipment Efficiency (%) = Availability X Performance Rate X Quality product Rate
MENGAPA OEE HARUS DIKONTROL?

PEFORMA AKAN NAIK

OEE
Pemeliharaan KAIZEN

Penurunan peforma mesin

Kondisi dies sudah out dari standar

Muncul trend NG Flash (inject. Plastik) (berkaitan dengan life time)

Dies aus, sehingga tidak rapat Dies di Improve

Kondisi dies sudah out dari standar Life time dies meningkat
(berkaitan dengan life time)

Usia Pakai Mesin

 Jam Kerja

07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00

Set UP

Mesin Rusak √
√
Istirahat
?
 PENGUMPUL DATA
(sensor, signal)

PENYALUR DATA

ALGORITMA AI

• Memberi • Predict Down time

peringatan jika • Keep Highly Efficiency
ada masalah • Keep Quality Level
CLOUD DATA VISUALISASI DATA
ANALISIS DATA

PROBLEM SOLVING
Thank You