Suggestion System :

“Peningkatan Aktivitas Cost

Reduction Material Laser Label
melalui Continues Improvement
dan Camera Inspection”

PT.TOYOTA MOTOR MANUFACTURING INDONESIA

Assy Painting Engineering Service Dept.
Kolaborasi Team : APPD – IT Div - Universitas
Perkenalan Diri ▸ Stuktur Organisasi :

Nama ILHAM DWI PRASETYO Divisi

Assy Painting Prod Div
No Registrasi 1425093
Departemen
Lama Bekerja 10 Tahun Engineering Service

Jabatan Staff Engineer

Shop Shop
- Tehnical Material & Logistic Support
Job Description - Cost Reduction & Budget Control Painting Assembly
- Project D3*D as Process Engineer ◉ Project
◉ Reguler
- 1st Winner SS AOP Group 2013
- Best VA Awards FY19
- 2nd Winner Cost Award FY20
Prestasi
- 1st Winner Cost Award FY21
- Best QCP Paperless Kaizen FY21
- Best QCP Cost Benefit Kaizen FY22
 Activity Step

01 02 03
Background Problem Scheduling

04 05 06
Solution Result Yokoten & Standarize
 01
Background
 1. Latar Belakang [External Factor]
I. [Ancaman] Domestic Market Share & Toyota Affiliates 3. Toyota Affiliates (AP Region) II. [Peluang] Customer Movement
1. Indonesia Market Share (Thousand Unit) 1. INA Customer Choice
Source : gaikindo.or.id (Jan-Oct 2023) Source : pwc.com 0,45
Significantly increase 0,4
0,33 0,34
xEV Segment 0,29 0,29
265 164 0,21
0,13 0,16
MS 32.1 % 106
68
67 29 TKM India TMT
20
ICE HEV EV ICE HEV EV ICE HEV EV
TOYOTA DAIHATSU HONDA MITSUBISHI SUZUKI HYUNDAI WULING
+1 yr +3 yr >5 yr
YoY +0.5% YoY +22%

Toyota maintain 1st MS leader. Korean & China significantly YoY 5 years ahead, xEV (HEV & EV)
are majority choice of customer in INA
growth, through xEV segment Dec 1st, 2023 Dec 16th, 2022
"Planned to enter Middle East "HILUX EV" launched
2. Rapid Growth of xEV Segment (Thousand Unit) Reg. Collab w/ local development 2. Customer Consideration (%)
Source : pwc.com
Source : fitchratings.com Enviromental Awareness
?
ID Govn't 32

Target Quality Experience 28

250% up Good Value for money 13 ❶ Customer

300% up Satisfaction (Quality)
Lower maintanance cost 12
400 2026 Nov 9th, 23 Lower operational cost 8 ❷ Competitive
50
3,1 21 Deal to build 1 new vehicle Deal w/ Thai Govn't Incentive Govn't 4
plant for GCC Prod EV Investment
2021 2022 2023 2025
Social Status 2 Manuf. Scope
Etc 1

xEV market are threat to domestic MS, grown significantly due to TMT are commited to be Asean Hub for EV ❶ Quality & ❷ Competitiveness become most
ambitious target 2025 TKM enter Middle East Market at 2024 considered parameter by customer

To maintain Toyota 1st MS in INA & respond Regional Movement [Ancaman] , TMMIN must to attack ❶ Quality & ❷
Competitivenes of xEV competitiors, As [Peluang] customer are rapidly move to xEV segment
 1. Latar Belakang [Internal Factor]
I. [Strength] TMMIN Future Challenge II. [Weakness] Pillar 0 ; Basic Foundation III. [Weakness] Pillar ❶ Competitiveness
1. Toyota Global Strategy 1. Shipping Quality Audit Δ [SR 2 Expansion & SR#3 Group Collaboration]
Carbon Neutrality Note : Safety are achieved Zero Accident (Jun-Oct'23) B-MPV Cost Plan Target X
2050 0,142 Rp 600.000 Rp696.342 Rp700.540 Rp667.421
P#1 P#2 Rp658.562
0,091 BMC

Rp/Unit
PHEV BEV FCEV HEV CN H2 0,074 Rp 300.000
Target 0.05 0,043 0,044 0.002 0.001
Toyota Global Strategy by "Multipathway" Rp263.271 Rp264.436 Rp258.136 Rp257.253
Rp 0
2. TMMIN Strategy Co st Plan Med o ar i Plan Accum . Act CR YTD
a. Road Map Jun Jul Aug Sep Oct TMT Kozui Assy Tar get (Dec '23) (Dec '23)
Source : APPD’s Hoshin Source : SQA Depy 2023
CR Target Not Yet Achieved [Gap – Rp8.632/u]
2. OK Ratio X C-MPV Cost Plan Target
P#1 P#2 X
3 Models Multiyear Project 1) Mature Electrification Target 92%
[BEV, etc] 74% 76% Rp 600.000 Rp630.165
Rp647.727 Rp604.874
69% 71% Rp598.433
2) Expand to New Biz 66%
95%
(Val. Chain, Mobility] Rp 300.000

Rp/Unit
*T/DNGA = Toyota/Daihatsu New Global Architectur Rp207.386 Rp214.784 Rp202.668 Rp203.377
Jun Jul Aug Sep Oct ASSB Rp 0
SR#1 – ❷ Source : QC Dept 2023 Co st Plan Med o ar i Plan Accum . Act CR YTD
Catch Up Incubation New Bussines Era! Tar get (Dec '23) (Dec '23)
Inhouse WTA Process 3. Prod. Eff Assy
❶ SR#2 Expansion X CR Target Not Yet Achieved [Gap – Rp8.285/u]
SR#2 – Beyond P#1 P#2
Tackling Fixed Cost SR#3 - Optime Group Collaboration Rp8.632/u Rp8.285/u
96,4 Target 95% 95 95 95,2 100%
5% 5%
B. TMMIN Focus Pillar 92,2
= Manuf. Scope = Workplace 89,3 90%
Pillar ❶ Pillar ❷ Pillar ❸ Pillar ❹ 96,4 89,3
92,2 95,2 80% 100% 95% 95%
Proved Global People Sustainable Carbon 70%
Competitiveness Transform. Business Neutrality 60%
Jun Jul Aug Sep Oct CR Target Act CR Medoari Act CR Medoari
Pillar 0 : Company Basic Foundation (S , Q , P) Source : CCR Dept 2023 P#1 #P1 P#2 #P2
To facing [Threat] & [Opportunity] Pillar ❶
Pillar 0 Competitiveness are threatened
of "Mature Electification" OK Ratio not yet achieve internal target
Pillar 0 & Pillar ❶ evaluation are needed by unattainable CR Target
TMMIN#2 urgently need to improve Quality KPI (OK Ratio) and also to achieve cost reduction target (Competitiveness)
as our Pillar 0 & Pillar ❶ to facing "Mature Electrification Era" , for Maintain MS Leader in Indonesia & Best AP No 1.
As Assy Cost Window Team, cost reduction target is priority
02
Masalah
 2. Masalah [Pencapaian KPI FY23]
Automotive Industry Competion Map Challenge Direction
Thinking Development

AUTOMOTIVE MARKET SHARE IN Needs to achieve challenge CR Target FY’23 Massive Review All Cost Structure by Various
by manufacturing best effort View Point
ASEAN
Singapura Labour Material Energy Depreciation
3% Lainnya
Vietnam 1% Nowadays Condition [KADAI]
9% Indonesia a. Gentan-I reduction is difficult due to actual
30% consumption has been in lower standard (LCL) ❶
Filipina Consumption Pricing
b. Gentan-I already review at project stage
11%

❸ ❷
Competitor Advantage Act Waste Act Usage
Malaysia
□ High Tech Not Easy :
17% ❶ Pricing
□ Low Price Expecting water by squeezing almost dry towel - Sourcing Benchmarking - Subtitute
Thailand
□ Design Modern - Localization
❷ Act Usage
- Packaging Review
29%
Source Data : Gaikindo Yellow Light for Toyota - Best Gentan-I
Takenaka-san’s Direction - Lower Standard
❸ Act Waste
Concept :
Selling Price Consept Various Squeezing Method to All Material
- Budomari
- Material Remain
- Leakage
- Repair

Cost + Profit = Selling Price Selling Price – Cost = Profit CR Assy#2 Progress [Rp/Unit]
(98 %)
Rp263.271 Rp257.253 Rp 6.018
Challenge to boost
↑
Selling Price

Profit Profit Profit Profit

Competitiveness Masalah!!!
CR by
OR Rp110.324 Rp 146.929
Direction 3
Cost
View Point
Cost Cost
Cost
Option 1 Option 2 Original CR Target CR Challenge Actual Achievement Remaining Medoari
 2. Masalah [Klarifikasi Masalah]
Cost Structure Progress CR View Point (Oct 2023)
Windshield Washer Hot Melt
Glass Primer
0,68% 0,58%
Butyl Tape Nox Rust 0,27%
Adhesive 1,07% 0,14%
Tape
7,46% Brake Oil Fluid
3,59%
Gasoline
27,05%
Glass Sealer
10,51%
CR Status 3 View Point :
base on Activity : ❶ Pricing

= Done 3 Activities LLC

Act Usage
12,43%
❷
Transmission
= Done 2 Activities Oil ❸ Act Waste
22,35%
A/C Gas [Bulk Supply - FY23 Activities]
= Done 1 Activity 13,87%

= Not Yet Activity

7.46% of Direct Material Assembly Plant #2 Still Have Potential CR [Adhesive Tape]
 2. Masalah [Klarifikasi Masalah]
01 Breakdown Direct Material Adhesive Tape 03 Flow Supply Direct Material Laser Label 05 Current Condition
Order by Sea Otodoke History Defect Outflow
Shipment Supply Installation
Laser Label Eksternal Outflow Internal Outflow
[Rp/Unit] 20
1 1 1
Rp11.220 0 case case case
Rp 12.000,00 case
Rp 8.000,00 Rp7.271
Rp4.142 TMMIN Warehouse Assembly Shop
Rp3.146 FY21 FY22 FY23 FY24 1250
Rp 4.000,00
Rp 0,00 Sourcing : Import Part
Case Defect Repair Methode
Focus Improvement Laser Label TAPE BT3005 BETA TAPE TAPE #735A
1. NG Character [6 case]
20MMX50M #2105 SCOTCH 20MMX50M
04 Flow Process Pemasangan di Assembly
❷ High Cost/Unit 3M 3M SEKISUI 2. Wrong Prod Year [12 Case]
*voice member 3. Miss Position [1 case]
02 Pengenalan Direct Material Laser Label 4. Miss Install [1 case]
❸* Loss Cost Component
No C a te g o ry % Lo ss

1 La b o u r 62%
Scan Barcode Manually Process Printing Check partial
2 M a te ria l 21%
character by Manually
Assembly Shop Inspection Shop 3 E n e rg y 17%

Installation BIQ Process QG Check CS Line Check Loss Cost Delay Delivery

Quality Matter ▶ Komitmen [ Goals ] :

TIS No : 00745-BZxxx
1. VIN Label [All Model]
▶ Kondisi Saat Ini
Cowl Side Area Center Pillar Area Ideal : 100% CR Target Challenge Achieved
2. GCC Label [Only GCC Model] *Potential CR :
Hasil Assesment QAN (Quality Assurance Network) - Printing GAP : ❶ Import Sourcing
Keterangan : 2% ❷ High Cost/Unit
∆ = NG ❸ Loss Cost repair
Assembly Q Gate Q Inspection
O = OK (ex Func A)
@
Actual : 98% CR Target Challenge Achieved
Center Pillar Area @ = OK
 2. Masalah [Klarifikasi Masalah]
( enba – enchi – enbutsu)

❶ Import Sourcing ❷ High Cost/Unit ❸ Loss Cost Repair

▶ Price Comparison (Price / meter) ▶ Gentan-I Consept Laser Label ▶ Loss Cost Component
Rp200.000 Rp149.609 Rp157.000 Rp129.300 is Actual Consumption + Acceptable Waste Is repair process occurred due to an outflow defect
Rp149.609 Rp125.800
Rp150.000
Rp100.000 Rp79.500 Rp98.700 ▶ Actual Consumption
Rp50.000 is material size needed refer to drawing standard ▶ Process Check
Rp0
Assy#1 Assy#2 ADM TMT ASSB TKM TMV TIS No : 00745-BZxxx Job Install Quality Gate Final 1
x mm

x mm
KAP
x mm

x mm
TMMIN Price Higher than Affiliate
Name Label Arabic Label
▶ How To Reduce Price ▶ Acceptable Waste
Idea Safety Quality Cost Delivery Possibility
Priority is actual waste obtained from trial results and has been
Idea approved
Challenge to
No Potential Short Time grasphing
Localiza Same Spec
Impact Big CR Delivery new local 1
tion sourcing
O O O O O
Long Time Mat Size 120m x 170m
Price No
Same Spec
Potential Delivery
Need Support
PUD and
● 8 Hours/Day ● 300 units/shift ● 6 variant
Negoitat Impact CR [import
TDEM Pricing 3
ion sourcing]
ember oice
O O ∆ ∆ ∆
NVW Increase due to walk
Change Challenge to Many character need
Part to see harigami
No Spec, Need Potential Short Time grasphing check
Subtituti Impact Approval Big CR Delivery new local 2
on Designer sourcing
Waste Ergonomi eye not good and Not Easy & Enjoyable
O X O O O position body bent Job
Reduce price material by localization Waste reduction by budomary activity

Self Challenge : Target :

“Achieve 100% CR Target Challenge by Reduce Cost/Unit of Laser Label Material 1. CR Achieve > Rp. 6.018,-/u
and Lost Cost Repair through approach New Technology” 2. Eliminate Loss Cost Repair
 03
Scheduling
 3. Schedulle Activity

2023 2024
Division
No Activity PIC
Supporting
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr

Plan
1 Study Potential CR Engser Prod, Mtn
Actual
Plan
2 Nemawashi Engser -
Actual
PCD, PPMD, PE, Plan
3 Koordinasi Engser MTN, PAD, ISTD Actual
PCD, PPMD, PE, Plan
4 Implementasi Engser MTN, PAD, ISTD Actual
Plan
5 Standarisasi Engser Prod, Mtn
Actual

Measurable Achievable Relevant

Spesific Optimis Material Laser
Time-bound
Target CR > Rp. terealisasi melalui
Target cost 6.018,-/unit Label belum Target terealisasi
reduction material continoues dilakukan review di Mar 2024
Laser Label improvement 3 view point
 04
Solution
 4. Solution [Pricing - Material Localization]
1 RISET & DATA ANALIZE 2 ACTIVITY PLAN 3 COUNTERMEASURE
Inspiration Idea : ▶ Idea Submission Initiative 1. Trial Activity
Together Trial w/: QD, Mtn, Prod
“Direct Online Shopping” PROD Pak saya kirim
1. Idea Propose
▶ Fact Data OK. WH PAD material free
Laser label material sourcing from Japan Good Idea Lets set meeting
LOG PAD
with all parties
⭢ Tax Import Cost ⭢ Transportation Cost Coordination Meeting
⭢ Regulation Rule ⭢ Global Price
▶ Riset
Looking for local supplier that have similar Victor I. S Tsuciya ID Engser
Adrianus P
material AES Mgr
SH AES
2. Evaluation Trial
Vehicle Part Structure Pak saya punya ide terkait
- Adhesive Evaluation - Defect Monitoring - Durability Test
lokalisasi material laser PUD PPMD PCD
Component Part Direct Material label VENDOR

2. Resources
Local Import Local Import Factor Kadai Countermeasure
Source Source Source Source No Have Scope Supplier Defect Bubble = 0 Case Result : OK
Man Collabs with PUD Team Result : OK
Knowledge
Alternative

Alternative

3. Material Registration
Machine No Impact -
T-Model D-Model Purchasing System Not Tehnical Material Follow Up Matrix Merit Demerit
Vendor submit sample Direct
Material Support to Make Order [not Merit Demerit
material trial free ❶
Similar ❶ Plug Plate Similar
existing mat] Material D-Model Difficult to
Material ❷ Label Material
❸ Wrap Guard Comparison Merit Demerit, Component Order by change
Different order methode, T- which is better between Component Part ekanban routing ADM
❷
⭢ List Supplier Candidat Methode Model by component & D- Component Part or Direct Part T-Model Material
Tsuciya Indonesia
❶ Plug Plate ❷ Label ❸ Wrap Guard Model by direct material Mat. And making ECR to
designer ❷ ECR Registration item Direct Easy maintain Add job order
Environment No Impact - ❶ VA Number W/H Material mat’ material
Proposal
PT. Tsuciya PT. Megah Nusantara PT. Kansai 3. Schedulle Activity 4. Implementation
Supplier Selection [Supported by PAD Warehouse] valuation mprovement
May Sep
No Activity PIC Apr 23 Jun 23 Jul 23 Aug 23 Jan 24 PDCA (Rp/u) Cost/Unit
Supplier Target Material
Supplier Feedback
Priority 23 23
Candidat Development Idea
Trial & asalah & olusi
1 AES
PT. Tsuciya
Indonesia
Have material that
meet required spec
1 Evaluation Implementation Plan
Masalah Solusi Rp. 11.220 CR Rp. 6.900/u
Material ECR Submission
PT. Megah Need Develop New 2 AES Process ECR Propose to change
Nusantara Material
2 Registration Rp. 4.320
Tsuciya-Nihon Submission routing by Order
PT. Kansai Need Develop New
Indonesia
Carbide AX0410
Material
2 3 Coordination AES very long time [RCR] Before After
 4. Solution [Actual Usage Reduction - Budomari Activity]
1 RISET & DATA ANALIZE 2 ACTIVITY PLAN 3 Countermeasure
Work Inspiration: ▶ Potential Budomari
❶ Reduce Length Material ❶ Change material dimention for length size
Coordination Meeting Supplier Challenge
Packaging Raw Material

100mm
120mm
Inspiration Idea :
“BUDOMARI ACTIVITY from PRESS Shop” Potential Budomari Increase 5.0%
▶ What’s the meaning of Budomari? ❷ Reduce Wide Material PUD SUPPLIER
Is japanesse term in the scope of 1. 1 Schedulle Activity Current Cond. Target Size
manufacturing industry which means good Apr-23 May-23 Jun-23 Jul-23 Aug-23 Sep-23 Oct-23 Nov-23 Dec-23 Jan-24
parts.
SUPPLIER MAT DEV’ TRIAL EQ MODIF IMPLEMENTATION
Ex. Budomari in industry tuna canning: SUPPLIER MAT DEV’ TRIAL EQ MODIF IMPLEMENTATION
Raw Materials for Tuna
Albacore is 5kg Potential Budomari Increase 25.8% RUN DOWN STOCK OLD MATERIAL 1ST ORDER NEW MATERIAL

Budomari = ▶ Riset IDEA RUN DOWN STOCK OLD MATERIAL USED STOCK MAT PLANT#1
After peel the skin, remove 2Kg / 5Kg x Idea 1 Idea 2 Idea 3 Idea 4 CUT OFF OLD MAT 1ST USAGE NEW MAT’
the bone, we only get 2kg 100% = 40%
VA Resize 1. 2 Equipment Modification Detail Modification Jig Stopper
▶ Budomari Laser Label Evaluation
Parameter
Change material
dimention
Review
Layout/Template
Template to be
Commonize
Template
small size Adjustable
Raw Material Actual Usage Bolt
Safety Same Condition

P = 120mm P = 85mm Same Quality Same Quality

Need Designer Need Designer
Quality Approval Approval Material
L = 26mm
L = 75mm O O X X
Productivity Same Condition Need Modif
Luas Permukaan = Panjang (P) x Lebar (L) Potential CR only Potential CR only Can't Direct Impact to Material
Cost Benefit Length Material Wide Material Cost Fix Bolt
Luas Raw Material = 120 x 75 = 9000 mm2 ∆ ∆ X
Luas actual Usage = 85 x 26 = 2210 mm2 Investment
Need Budget for Need Budget for Need Budget for Need Budget for 1. 3 Trial Evaluation (Trial = 30unit) valuation mprovement
Modif Jig Update Program Update Program Update Program Defect NG Root Cause
Budget Evaluation Methode Result
Budomari = ∆ ∆ ∆ ∆

2210 mm2 / 9000 mm2 x 100% = Increase Budomari by : Adhesive Strength Test OK
❶ Change material dimention for length size
24.5%
Monitoring Defect NG
❷ Review Template for wide size Durability Test OK Appearance NG Difficult to Release
 4. Solution [Actual Usage Reduction - Budomari Activity]
➊
asalah valuation mprovement
Narrow Space From Left to Right Opsi 1
From Right to Left
Opsi
2 Improvement Result
Cost/Unit

PDCA and PDCA CR Rp. 876/u

Rp. 4.320
can Achieve Target
Resetting Template Budomari = Rp. 3.444
Difficult to Release Name
Label due to Narrow Space Change direction ⭢ Setting Program to Move 2210 mm2 / 7500 mm2 x 100% =
Work Position Installation method release Position Template 29.5% Before After

❷ Review Template for Wide Size

2.1 Schedulle Activity 2.2 Setting Template [Genba Genchi Genbutsu] 2. 3 Trial Evaluation (GCC Model) 2. 4 Trial Evaluation (Non GCC)
Apr-23 May-23 Jun-23 Jul-23 Aug-23 Current Situation Evaluation Result Evaluation Result
Safety NG Quality NG
Program Productivity NG
TRI IMPLEMEN Quality OK
Template 20mm 5mm
Setting
AL TATION Video
Productivity NG
Program Workability NG
TRI IMPLEMEN NG Tear
Template 20mm
AL TATION Need Space Allowance Wide Size due to Need Space Allowance Wide Size due to
Setting
process Manual Cutting process Manual Cutting
PDCA ❶ PDCA ❷ 2.5 Schedulle Activity valuation mprovement
asalah & olution Additional Information Current Equipment can not support to improve Auto Cutting.
CAPEX
▪ Equip Laser Label is Pareto Line Stop Improvement Auto Cutting carried out in simultan with CAPEX Activity
FY23
Masalah Solusi ▪ As Critical process may impact to function issue 2210 mm2 /
4000 mm2 x
Improve Jun-23 Jul-23 Aug-23 Sep-23 Oct-23 Nov-23 Dec-23 100% =
No Kadai/Voice Member Direct Cause Target
ment 55.3%
1 Outflow problemer High Frek Result Print Out NG
Can’t Setting New Equipment Development
Template due Improve manual 2 High cost for repair Can't criple due to impact next process
New Equipment Development After Condition
to Need Space cutting to Auto Provide
Difficult to stock sparepart due to
3 Equipme CAPEX Setting Parameter TRI IMPLEMEN
for Manual Cutting Long Time Problem special vendor
nt for FY23 Rp. 3.444 CR Rp. 1.607/u
Solving Difficult to follow up problem to Power Laser AL TATION
Cutting 4 Back Up
special vendor Setting Parameter TRI IMPLEMEN Rp. 1.837
High frek equipment
5 Lifetime equipment > 10Years Power Laser AL TATION
error Before After
 4. Solution [Waste Reduction – Improve by Camera Inspection]
Detail Aplication

Inspiration Idea :
“Tilang Online by Camera”
Before Condition
Assembly Q Gate QC
asalah
Inspection
Team Member only check 5
digits latest of Frame Number
@
After Condition

Assembly Q Gate QC Inspection

TM Not Follow QA-N
Requirement
Difficult to check all
Character @
 Road Map 100%
New System AUTOMATION
Development
 Collab with ISTD Team to Develop
Strengthen Foundation  Benchmark P#1 New
Auto Printing
Equipment  PDCA Activity
 Current Process Review &
Compare with
 PDCA Activity
Feasibility Study
User Requirement Grasphing  Pokayoke Camera Vision
AVI Data

 Spec Requirement Study

2022 1 2023 2 2024 3

Hardware Hardware Installation

Procurement & New System SS Panel Procurement
 05
Result
 5. Result
▶ Tangible / Monetary ◀ ▶ Intangible / Non Monetary ◀
roductivity ost afety uality Devpt
Item Nominal Cost
Tidak ada outflow defect
Total Prod. per Item Biaya (Rp) Safety Case
hari
600 unit
Camera 400 jt 1 20 Enjoyable Working

Kasus
Modif jIg 5 jt 0,8
Cost per jam Rp 104.000
MH LABOUR OT 5 jt 0,6
0,4
Zero Case Ergonomi Issue
Reduce
10 detik
Lain Lain 10 jt
0,2 0 voice member
(sec/unit) Struktur & Installasi 25 jt 0
Defect pada name label dapat
eliminated
(Total Prod X Reduce TOTAL 445 jt
Total Reduce X hari kerja X dicegah menggunakan Camera
12bulan) / 60menit Benefit Inspeksi dengan AI Increase Skill
(10X 600unt X 22hr Item Biaya (Rp) mengenai system
X 12bln) / 3600 Tidak ada kasus safety accident Level up Traceability
detik Man Hour Rp. 45.760.000 maupun incident selama Camera Vision
improvement berlangsung maupun Untuk memberikan bukti terjadinya
Rp. 8091/unit
440 MH/Tahun sesudah ketidaknormalan [Next Activity]
Cost Material Rp.
Rp 1.281.614.400
45.760.000/Tahun TOTAL 1.327 bio thers estimoni
Reduce 10 sec/114 sec 1) Camera Inspeksi menjadi salah satu Member Quality Gate Management
Break Even Point (BEP)
= Rp 45.760.000/Tahun use case Smart Quality pada Shopjiku
= 0.298 Tahun
Assy Shop
2) Cust. puas karena pengiriman tepat
atio et uality ncome waktu ABdi Mr. Victor – AES Dept Head
(Benefit Prj. – Cost Prj.) 882 jt “Proses menjadi mudah
3) Menjunjung tinggi nama baik dan Pekerjaan “Yokoten ke Assy 2”
Perusahaan Menyenangkan”
Cost Prj. 452,2 jt
 5. Result
▶ Komitmen [ Goals ] :
CR Challenge Target Achieve 100%
PENCAPAIAN CR FY23 [REALISASI 101%]
Rp268.000
Rp 8.091/unit
CR #3 Rp. 315/unit
Rp 6.018/unit Rp265.344
Rp265.059 Rp265.059
Rp264.153 CR #2 Rp. 876/unit
Rp264.000 Target Aktual Realisasi

CR #1 Rp. 6900/unit
Rp260.000

Rp263.271
Rp256.000
Rp257.253 Rp257.253 Rp257.253 Rp257.253 Rp257.253

Rp252.000
CR Challenge Act CR YTD Jan-24 Feb-24 Mar-24 Apr-24
Target Dec 23
 06
Standarize
 6. Standarize
▶ EIS ▶ IT ▶ MASTER TEMPLATE

▶ Lembar Evaluasi Training ▶ Approval Drawing ▶ BIRA PROBLEM ▶ FLOW ABNORMAILITY

●●●● 指導できる Can teach other member
●●●○ 理解し１人で出来る Can understand myself
New Laser Label Printer Machine ●●○○ 補助が有れば出来る Can do by observe
●○○○ 聞き取りにて理解出来る Can understand by interview

優先度 Status Le ve l of Un de rstan din g

ＮＯ Item Understanding Item (Priority)
PIC
(After) MP 1 MP 2 MP 3 MP 4 MP 5
Know the Power source position ( Panel, Air, etc ) : Main breaker, air
1 Knowledge ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
header & hand valve, oils and hand valve position
Know the Lock out point at MCB, Exaust Valve, Emg Stop, or Door Switch
2 Knowledge ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
that installed in MC
Know the Emg Stop,Door SW, Safety Bumper, Temporary / Fixed
3 Knowledge ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
position stop, other that installed in MC
Know the Master On area, Safety Device arrangement ( TLS ), Explain
ロ 4 Knowledge
interlock condition between other equipment
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

ボ 5 Knowledge Ｋ Know the equipment summary (overall), Cycle time and Sequence Prosess ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Ｓ
ッ ｔ
ｎ
ｏ
6 Knowledge
ｒ Know the Equipment Hazard Explanation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
ト ｕ
ｗ
ｌ
7 ｃ Know methode and quality confirm ( Label Judgement ) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
本 Knowledge
ｔ
ｅ
ｄ Know Vehicle input data method (Scanner Barcode, AVI, Manual input
体 8 Knowledge
ｕ
ｒ
ｇ
and by pass method)
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
ｅ
ｅ Know the content each of screen : Monitoring proses, special function,
・
9 Knowledge ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
setting function.
10 Knowledge Know the normal condition Operation Machine (MC) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Know the interlock equiment & Condition Normal ( to Laser marking
11 Knowledge ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
& Camera judgement )
Know the interlock to other equipment & Conditon Normal (
12 Knowledge ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Conveyor & LCP/AVI )
13 Knowledge ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

14 Operation Start up Equipment & Shutdown Equipment ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

15 Operation Manual operation for each process ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

16 Operation Can Remark Proses Marking Label ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

17 Operation Can auto operate and know normal condition before after ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

18 Operation Can bypass interlock pokayoke ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

19 Operation Explanation Interlock change timing ( start, jdg, send data timing ) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

20 Operation Can use spesial function MC ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

21 Operation Explanation Label judgement camera ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Upload/Backup PLC, Module spesial cyl, Control Laser, Control camera,
22 Operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
PC, Monitor, HMI
23 Operation *Backup, Edit & Transfer Program HMI Keyence ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

24 Operation
Ｏ
*Spesial Setting Parameter HMI Keyence ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
ｐ
25 Operation ｅ *Backup, Edit & Transfer Program PLC ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
ｒ
26 Operation ａ *Spesial Setting Parameter PLC ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
ｔ
27 Operation ｉ *Backup, Edit & Transfer Program Spesial Module Cyl ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
ｏ
ｎ
28 Operation *Spesial Setting Parameter Spesial Module Cyl ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

29 Operation *Backup, Edit ( Teach )& Transfer Program Contoller Camera ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

30 Operation *Spesial Setting Parameter Controller Camera ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

31 Operation *Backup, Edit ( Teach )& Transfer Program Laser Marking ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

32 Operation *Spesial Setting Parameter Laser Marking ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

33 Operation *Backup, Edit & Transfer Program HMI Omron ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

34 Operation *Spesial Setting Parameter HMI Omron ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

35 Operation *Backup, Edit & Transfer Program PC & software running ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

36 Operation *Spesial Setting Parameter PC & Software running ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

THANKS!

ILHAM DP
Assy Engser Plant 2

[email protected]
[email protected]
+62 8111-818-489