Kami Ingin Seperti Super Hero Dimana Di Akhir Cerita Film

Mereka Selalu Menjadi Pemenang

 Perkenalan Area Kerja

Kontribusi Diepress Casting Dalam Pembuatan Sebuah Mobil

Diepress Casting
Mesin Press

Die
Didirikan : 09 September 1997
Kapasitas : 120 ton/bulan
r

Mesin press Luas Area : 1,266 m²

Material cetakan Sub Body Assy – Welding
Body mobil pembuat body MP : 16 MP Main body
Jumlahbody Mobil Toyota

Ilustrasi Proses Die Stamping Product (Die Press)

(Cetakan Die Stamping)

 Perkenalan Area Kerja
1. Die Press Casting Process Flow
Carbon and Pouring liquid Disassembling Cleaning
Filling and compaction Making molten metal metal into the mold flask and the
Isomol
of sand work piece work piece
Coating
d
d d
us
u u d
t
st st us
t

Coating Moulding Melting Pouring Disassy Finishing

2. Die Press Casting Products and Markets

Products Indonesia Domestic: Market Toyota Group from Indonesia
- PT. Toyota Astra
- PT. Astra Daihatsu Trade Balance
Stamping Dies - PT. Hino Motor
Overseas Market:
- Asia Pacific
Injection Mold Dies
- Middle East
Overseas Plant:

Part (Component) - 24 Affiliates Exported 14 to Countries

 Perkenalan Anggota Group

Rata – rata usia : 30,7 tahun

Organisasi Rata – rata masa kerja : 10,5 tahun
Suwanto B Circle Leader
THEMA Ke 20
1st 2 Januari 2009

Supriyanto
Irfan B
Sulisdiyanto
Ekwan
M. Teguh T Theme Leader A. Basith M. Fadil

PRESTASI Group 2. Company 2018

QCC Reward 1. Division Convention
2021
Convention 2nd
2014 2015 2016 2017
4th
6th 6th 6th
1 st

2014 - 2021 Our Dreams

The Last Achievement : 2nd place in TAM -
Juara 1 Directorat
1st place 6 times in a row in 7 years TMMIN
Perkenalan Circle Leader

Circle Leader
Team Leader
- Juara 2 QCC TAM-TMMIN
- Juara 2 QCC Directorat

Team Member
- Juara 1 Skill Contest TMMIN
- Juara 1 Skill Contest Thailand

- Sukoharjo , Jawa Tengah

 Current Assessment Group

2019 2020 2021

Theme : Theme : Menurunkan NG Komposisi
Theme :
Menurunkan NG komposisi
Menurunkan defect Dakon
Seng (Zn) pouring

Achievement : Achievement;
Target: Juara 1 Konvensi Directorat 2021
Juara 7 Konvensi TAM-TMMIN 2019 Not Konvensi
X : 2,8 X : 3,0 X : 3,0 X : 3,3 X : 3,2 X : 3,4
Y : 2,9 Y : 3,1 Y : 3,1 Y : 3,5 Y : 3,4 Y : 3,6
X : 3,2
Y : 3,4 X = 3,2
X =3,0
Y =3,1 Y = 3,4

Zone C Zone B
COVID-19

ZONE A 2 MP ZONE A 2 MP ZONE A 2 MP

ZONE B 3 MP ZONE B 3 MP ZONE B 1 MP
ZONE C 2 MP ZONE C 2 MP ZONE C 3 MP
ZONE D 1 MP ZONE D 0 MP ZONE D 2 MP

Avg Skill = 64,3 % Avg Skill = 66,3 % Avg Skill = 69,3%

 Breakdown Assessment Group
Mapping Assesment Member Breakdown Assesmeent Member Berdasarkan Point Mapping
X axis category Y axis category
Assesment Group

ZONE
NAME

Meeting
Solving

7NTools

Komunikasi
work

4s & Safety
8 Step

Leadership

Status
Multi Skill
7 Tool

Metting

Motivasi
Team
Kaizen
Target
Supriyanto

work
X Y X : 3,4

Team
Step
SUWANTO 5,0 5,0 5,0 5,0 5,0 5,0 5,0 5,0 5,0 5,0 5,0 5,0 A Y : 3,6
TEGUH 4,0 4,0 4,0 5,0 4,0 4,2 4,0 4,0 5,0 4,0 5,0 4,4 A

Irfan SUPRIYANTO 4,0 4,0 4,0 5,0 2

2,0 3,8 4,0 4,0 4,0 4,0 5,0 4,2 B

BASITH 3,0 3,0 3,0 4,0 4,0 3,4 3,0 3,0 3,0 4,0 4,0 3,4 B

SULIS 2,0 3,0 3,0 3,0 3,0 2,8 3,0 2,0 4,0 3,0 4,0 3,2 C Current
Fadil EKWAN P 2,0 3,0 3,0 3,0 3,0 2,8 3,0 2,0 3,0 3,0 4,0 3,0 C
X : 3,2
1 Y : 3,4
IRFAN B 1
1,0 2,0 1,0 2,0 2,0 1,6 1,0 1,0 2,0 3,0 2,0 1,8 D

FADIL 1
1,0 2,0 1
1,0 2,0 2,0 1,6 1,0 1,0 2,0 3,0 2,0 1,8 D

AVERAGE 2,8 3,3 3,0 3,6 3,1 3,2 3,0 2,8

3,0 2,8 3,5 3,6 3,9 3,4

Weaknees Sumbu X Weaknees Sumbu Y

Sumbu X (a,c) : Sumbu X (e) : Sumbu Y (b):
1 8 Step dan 7 tool rendah
2 Kaizen rendah
3 Status meeting turun
4 Sumbu Y (a):
TeamWork menurun
Sumbu X

Sumbu Y
Covid -19

2 Mp baru belum paham Target kaizen man : 3 mp

8 step dan 7 tool Actual Kaizen man : 2 Mp Proses meeting Terkendala covid 19 Ada Gap antara senior dan junior

Kami memilki 4 Weakness

 Strategi dan Target Assessment

CHANGE & CHALLENGE

by COMMITMENT X COMPETENCY X CONSISTENCY

 Enjoying
 Bersahabat
 Smart Training
 menyenangkan
 Inovasi training
 Guide Training
PENINGKATAN SUCCESS
CHECK PELATIHAN SKILL MOTIVASI & KOMUNIKASI
Assessment Development Result

1. Sumbu Xa (8step) : Membuat Inovasi terkait metode belajar

4 Strategi

2. Sumbu Xe (Kaizen) : Mengirim Mr. S untuk Training Karakuri

3. Sumbu Yb (Status meeting) : Membuat inovasi terkait meeting QCC
4. Sumbu Ya (Teamwork) : Mengadakan acara kebersamaan (Games, trakking,Dan lain-lain)
 Aktifitas Circle Leader
Strategi 1 : Membuat Inovasi terkait methode belajar atau training QCC
A. Problem B. Action
Aplikasi Training
Skill 2 Mp junior di sumbu X masih rendah 1. Meyediakan waktu dan tempat training khusus
2. Dibuatkan Aplikasi Training G-QCC

G-QCC 7 Tool
Waktu Training
dilakukan selepas
kerja normal

Mr. Irfan Mr. fadil

• Belum tahu apa itu G-QCC • Member Antusias mengikuti Training

• Belum bisa mempraktekan 7 tools • Kemauan untuk belajar tinggi

Result : Skill 2 Mp Junior meningkat, Assessment sumbu X naik 3,3 point

 Aktifitas Circle Leader
Strategi 2 : Skill Up Kaizen Mr. Supriyanto dengan Training Karakuri
A. Problem B. Action Foto hasil training karakuri
• Skill Kaizen Mr. Supri masih rendah
• Mengirim Mr. Supri training karakuri
diantara anggota senior yang lain
internal (Trainer bp. Syarip)
Target kaizen man : 3 mp • Menugaskan Mr. Supri untuk menjadi
Actual Kaizen man : 2 Mp leader dalam penanggulangan Qcc

Kamu jadi In Class

Kaizenman
Kaizen
selanjutnya
Man???
Foto dengan
Couching M. syarif/Suranto
member (Master karakuri) Foto sedang
Praktek lego training)

Foto sedang
training)

Result : Skill Up Mr. Supri berhasil point assesment naik 4,0

 Step 0-1: Pemilihan Thema
BRAINSTROAMING PEMILIHAN THEMA BERDASARKAN SARAN ANGGOTA
No. Nama Voice Member Usulan Thema S Q C P HR
1 Basith Pengambilan scrap lama Menurunkan waktu Charging - - - V V
2 Teguh Hasil komposisi pouring dari analist banyak NG Menghilangkan NG komposisi pouring V V V V V
3 Supri Defect Yakitsuki banyak Menurunkan defect Yakitsuki V V V V V
4 Irfan Pembuangan terak banyak dan sulit Menghilangkan defect terak V V V V V
5 Sulis Jarak saat pouring terlalu dekat Mengurangi radiasi panas saat pouring V - - V V
6 Fadil Operator sering salah hitung material komposisi Menurunkan NG komposisi melting - V V V -
7 Ekwan Pemakaian Garpu terak borors Menurunkan pemakaian garpu terak - - V V -

Evaluation Point usulan Thema THEMA

Evaluation Item
Total
No Usulan Thema

Menghilangkan
Urgensi Durasi Dampak Performa Point
Cost
thema thema problem kerja

15 NG Komposisi
Menghilangkan 1. Urgent 1. 12 Bulan 1. Defect 1. 100 juta 1. 25 %
1 NG Komposisi 2. Sedang 2. 9 Bulan 2.Complaint 2. 50 Juta 2. 50 %
Pouring 3. Sangat Urgent 3. 6 bulan 3. Reject 3. 10 juta 3. 100%

Menurunkan 1. Urgent 1. 12 Bulan 1. Defect 1. 100 juta 1. 25 %

Pouring
2
Defect Terak
2. Sedang
3. Sangat Urgent
2.
3.
9 Bulan
6 bulan
2.
3.
Complaint
Reject
2.
3.
50 Juta
10 juta
2.
3.
50 %
100%
11
1. Urgent 1. 12 Bulan 1. Defect 1. 100 juta 1. 25 %
Menurunkan
3 2. Sedang
Defect Yakitsuki 3. Sangat Urgent
2.
3.
9 Bulan
6 bulan
2.
3.
Complaint
Reject
2.
3.
50 Juta
10 juta
2.
3.
50 %
100%
10
 Step 0-1: Pemilihan Thema

Apa sih NG komposisi Pouring itu ??

Hasil pengecekkan komposisi kimia setelah proses pouring

di nyatakan di luar standart
Flow Process Melting & Pouring Menganalisa komposisi kimia molten metal
dengan :

ProsesTerjadinya Problem
M/C Analyzer M/C Spectro

Check Penambahan Slag Slag Check Lanjut

Melting Check
Komposisi Magnesium Tapping Remover Remover Pouring Komposisi
Process Temperatur
Melting Trearment 1 2 Pouring

Replay No Replay
Buang

Bisa dilakukan adjust Tidak bisa dilakukan

komposisi adjust komposisi
 Step 0-1: Pemilihan Thema
NEGATIF EFFECT DEFECT TERHADAP ASPEK SQCPHR+D

S afety Operator
Terkena
pecahan Die
Die Retak/Pecah
C ost
• Jika ada kesalahan komposisi kimia yang
berlanjut ke produk finish maka akan berdampak
serius terhadap benda kerja
 Die retak/pecah

Quality Image toyota turun

Complaint Costumer
Hitung Kerugian

“REJECT” 1 BENDA KERJA AKIBAT DIES NG

1 Kg FCD = Rp. 22.000,
• Jika sampai ke tangan konsumen
= (6150 Kg X Rp.22.000,-)
bisa memperburuk citra
perusahaan = Rp.135.300.000,-

Productivitas Proses buat baru 8 day

HR Development
Sebagai
Tantangan untuk
• Jika Product NG
Leadtime : Delay • Ada tidak membuat
dilakukan proses 16 day pekerjaan
Gap 8 produk gagal
Pembuatan ulang hari tambahan
Proses buat ulang
& SKILL UP
 Step 0-1: Pemilihan Thema
Action Plant Hubungan Thema dengan Hosin
Divisi,Departement, dan Section
TOYOTA MOTOR MANUFACTURING INDONESIA Director SMEC Division

DIVISION ACTION PLAN FY 2021/2022

CASTING : DIVISION I.Nyoman W. Masui Kubota
Tagor JD
Juganda S.

1.1 Eliminite muda proces

KPI FY 2020/2021 Dept.
Resources
Company Hoshin Target
No. Division Action in Manpower Budget
Current Target Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Charge
Ref No Mgr PIC Invest. Expenses

PRIORITY THEME :

2.1 Zero Out Flow & Claim Customer

TOYOTA MOTOR MANUFACTURING INDONESIA Director SMEC Division
I. Inhouse Competitiveness
1 DIVISION ACTION PLAN FY 2021/2022
A SAFETY A.1 Work Accident Zero Accident Zero Accident Implementation

PDCA
Eng Suranto Haddy P
A.1. Countinue Safety Daily Management A.1.1. Implementation PMRs Safety by SGA board 80% 100% Eng Suranto Haddy P
CASTING : DIVISION A.1.2. Comply SMK3 Gold 100% Gold 100% PDCA Eng Suranto Haddy
I.Nyoman W. P Masui Kubota
Tagor JD

2.1.2 Review build in quality in each process

Audit Juganda S.
A.1.2. Rank Down Actifity 1 / Month 1 / Month Prepare Eng Suranto Haddy P
KPI FY 2020/2021 Dept.
Resources
Company Hoshin Target
No. Division Action in Manpower Budget
Current Target Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Charge
Ref No Prepare SVP Mgr PIC Invest. Expenses
A.2. Strengthen ownership by develop comfort workplace
A.2.1. Forkliftless Activity at Casting Factory 1202 m2 562 m2 Eng Suranto Haddy P
PRIORITY THEME : Prepare Prepare Prepare

(Claim customer)
Forkliftless A.2.2. Eliminate work at high place Zero Zero M/T A.Kohar Toto W.
3000 I. Reduction
Inhouse Competitiveness
2121 Implementation
1 A SAFETY A.1 Work Accident
TOYOTA MOTOR MANUFACTURING INDONESIA Zero Accident Zero Accident Eng Suranto Haddy P Director SMEC Division
2000 1617 PDCA
A.1. Countinue Safety Daily Management A.1.1. Implementation PMRs Safety by SGA board 80% 100% Eng Suranto Haddy P
DIVISION ACTION PLAN FY 2021/2022

M2
1202 1174
818 A.1.2. Comply SMK3 Gold 100% Gold 100% PDCA Eng Suranto Haddy P
1000
Prepare Audit
A.1.2. Rank Down Actifity 1 / Month 1 / Month Eng Suranto Haddy P
CASTING : DIVISION
Tagor J.D
Tagor JD
0 I.Nyoman W. Masui Kubota
FY17
FY16 FY18
FY17 FY19
FY18 FY20
FY19 BM Juganda S.
Prepare SVP
KPI FY 2020/2021 Resources
A.3. Reduce work difficulties (yarinikui shigoto) ownership by developNo.
A.2. Strengthen comfort workplace
A.2.1. Forkliftless
Company Activity
Hoshin at Casting Factory
Target 1202 m2 562 m2 Prepare Prepare Prepare
Eng Suranto Haddy P Dept.
Division Action in Manpower Budget

Division Head EPSD

3000 Forkliftless Reduction Ref No A.2.2. Eliminate work at high place Zero Zero Current Target Apr May Jun M/T
Jul Aug A.Kohar Toto
Sep Oct Nov W. Jan
Dec Feb Mar Charge
Remain Rank at Casting Mgr PIC Invest. Expenses
2121 A.2.2. Rank down activity
Rank A Rank B Rank2000
C
1617 A.2.2.1 Melting pouring
PRIORITY THEME : Prepare SVP
8 Rank B Rank C Eng Suranto Hariansyah

Juganda S

M2
8 1202 I. Inhouse Competitiveness
1174
6 6 6 6 1000 818 Implementation
6 1 A SAFETY A.1 Work Accident
Prepare
Zero Accident
SVP
Zero Accident Eng Suranto Haddy P
A.2.3. improve achievement of efficiency A.1.1.PEFF 0,92 PMRsPEFF 1,0by SGA board M/T
100% A.Kohar Toto W. PDCA

Rank
4 4 A.1. Countinue Safety Daily Management
0
Implementation Safety 80% Eng Suranto Haddy P
6

Deputi Division Head

FY17
FY16 FY18
FY17 FY19
FY18 FY20
FY19 BM A.1.2. Comply SMK3 Gold 100% Gold 100% PDCA Eng Suranto Haddy P
2 4 4
2 A.1.2. Rank Down Actifity 1 / Month 1 / Month Prepare Audit
Eng Suranto Haddy P
0 A.3. Reduce work difficulties (yarinikui shigoto)
FY17
FY16 FY17
FY18 FY18
FY19 FY19
FY20 BM
Remain Rank at Casting
A.2.2. Rank down activity
Eng Suranto Hariansyah
Prepare SVP
Rank A Rank B Rank C Prepare
B ENVIRONMENT 8 A.2. Strengthen ownership
A.2.2.1 by develop comfort workplace
Melting pouring A.2.1. Forkliftless Activity at Casting Factory Rank B Rank C 1202 m2 562 m2 SVP
Prepare Eng Suranto
Prepare Hariansyah
Prepare
Eng Suranto Haddy P
Mapping
B.1. Energy Efficiency 8 B.1.1. Reduce Running Equipment after A.2.2. Eliminate work at high place Zero
Implementation Zero A.Kohar M/T A.Kohar Toto W.
6 6 6 6 3000Production off
Forkliftless Reduction N/A Reduce 30% M/T Toto W.
6 Prepare SVP
2121 achievement of efficiency
A.2.3. improve PEFF 0,92 PEFF 1,0 M/T A.Kohar Toto W.

Rank
4 4 2000 1617
6

M2
2 4 4 1202 1174
B.2. Water Efficiency 2 1000 818
0 Prepare Implementation
Water FY17
FY16 B.2.1.
FY17 Reduce
FY18 FY18
FY19 water consumption
FY19
FY20 BM of production prosess N/A 0,0444 m3/unit M/T A.Kohar Toto W.
0,15 0,139 0,128 0,13 0
0,121 0,114 FY17 FY18 FY19 FY20
Eng Suranto Hariansyah
FY16 FY17 FY18 FY19 BM

(m3/unit)
0,10 B ENVIRONMENT
A.3. B.1.1.
ReduceReduce
work difficulties (yarinikui shigoto) Mapping
B.1. Energy Efficiency Running Equipment after Production off N/A Reduce 30% Implementation M/T A.Kohar Toto W.
0,05
Remain Rank at Casting

2.1.1 Meningkatkan leadtime product (No delay)

0,00 A.2.2. Rank down activity
FY 16 FY18
FY17 FY19
FY 17 FY FY20
18 FY 19 BM Rank A Rank B Rank C Prepare SVP
B.2. Water Efficiency 8 A.2.2.1 Melting pouring Rank B Rank C Eng Suranto Hariansyah
B.3. Waste Reduction 8 Prepare
6 6 6 6 Prepare Implementation
Water B.2.1.
6 Reduce water consumption of production prosess N/A 0,0444 m3/unit Implementation M/T A.Kohar Toto W.
0,139B.3.1. N/A Reduce 5 % M/T
9,0 8,86
Waste 0,15 0,128 Waste
0,121
Reduction
0,13 : A.2.3. improve achievement of efficiency PEFF 0,92 PEFF 1,0 A.Kohar Toto W. Prepare SVP
M/T A.Kohar Toto W.

Rank
8,62 0,114 4 4
6

2.1.2 Menghilangkan proses muda dan reject product

(m3/unit)
8,39 8,40,10

(Ton/unit)
8,5 8,17 2 4 4
0,05 2
8,0 0
FY17
FY16 FY17
FY18 FY18
FY19 FY19
FY20 BM
0,00
7,5 FY19 Eng Suranto Hariansyah
FY 16
FY17 FY18
FY 17 FY19
FY 18 FY20
FY 19 BM FY 16 FY18
FY17 FY 17 FY FY20
18 FY 19 BM
B.3. Waste Reduction B ENVIRONMENT
Prepare Mapping
B.1. B.3.1.
EnergyWaste
Efficiency B.1.1. Reduce Running Equipment after Production off N/A Implementation
Reduce 30% Implementation M/T A.Kohar Toto W.
B.4. CO2 reduction 8,86
Waste Reduction : N/A Reduce 5 % M/T A.Kohar Toto W.
9,0 Prepare Implementation
CO2 B.4.1.
8,62 CO2 reduction
8,39
Energy
8,4
saving through reduce unnecessary process (non Production) 0.053 Ton / Unit 0.048 Ton / Unit M/T A.Kohar Toto W.

(Ton/unit)
0,134 0,133 8,5 8,17
0,132
(Ton/unit)
0,132 0,131 8,0 B.2. Water Efficiency
Prepare

Suranto
Implementation
0,13 0,13
7,5 Water B.2.1. Reduce water consumption of production prosess N/A 0,0444 m3/unit M/T A.Kohar Toto W.
0,130 FY 16
FY17 FY18
FY 17 FY19
FY 18 FY20
FY 19 BM 0,15 0,139 0,128 0,13
0,121 0,114
0,128

(m3/unit)
0,10
FY17
FY 16 FY18
FY 17 FY19
FY 18 B.4.
FY20
FY 19 CO2
BM reduction

Departement Head Produksi

0,05 Prepare Implementation
CO2 B.4.1. CO2 reduction
Energy saving through reduce unnecessary process (non Production) 0.053 Ton / Unit 0.048Board
Ton / Unit
Kick off Quality M/T A.Kohar Toto W.
2 QUALITY 0,134 0,133 0,00
Build In Quality
Visualization
Campaign
0,132 Socialization PDCA
FY17 FY18 FY19 FY20
build in quality in eachFY process
16 FY 17 FY 18 FY 19 BM

(Ton/unit)
0,132
2.1. Zero Out Flow & Claim Customer 2.1.1. Review
0,131 (Outflow) Zero Outflow Zero Outflow Eng Suranto Rio K.
0,13 0,13 B.3. Waste Reduction
0,130 Prepare
2.1.2 Eliminate reject die casting (No Re-Casting)
Waste ZeroReduction
B.3.1. Waste Re-casting
: Zero Re-casting SimulationN/A Eng 5 Suranto
Reduce % Rio K. Implementation
M/T A.Kohar Toto W.
9,0 8,86 Trial &
2.2. Increase Quality Achievement Continous 0,128
Improvement 2.2.1.
Next Process Defect 8,62Reduction by: Defect Next process : Process Die design
FY19 FY20 FY17 FY18 Evaluation
FY 18 FY 19 BM FY 16 FY 17 8,39 8,4 Study

(Ton/unit)
Defect Next Process 8,5
6,23919564
2.2.1.1 Achieve uniform solidification by gating system 8,17 Eng
Kick off Quality Suranto Rio K.
4,760291302 1TR QUALITY
2TR Cams 0,50% 0,40% Build In Quality Board
8,0
6,0
2
1,96164966 6 2,94720717 design improvement 8,0 Socialization Visualization
Campaign
PDCA
0,980535631,71047572 3,26
0,97165511 2.1.
1,5 Zero
0,67Out Flow & Claim
2.2.1.2 Customer 2.1.1.
7,5 Review buildby in quality in each process (Outflow) Zero Outflow Portable burner
Zeroinstallation
Outflow Eng Suranto Rio K.
4,0 8 5 Furnace RCS improvement
%

3,297010331,006540220,64907711 Eliminate excess gas source while pouring Eng Suranto Rio K.
2,0 6 8 1,32647494 1,54
8 7
2,04327535 4
7 0,4
0,5
0,6 1,05 FY 16 FY
FY17 FY18 FY19
17 FY FY20
18 FY 19 BM
0,0 3
FY17
FY16 FY18
FY17 FY19
FY18 FY20
FY19 BM 2.1.2 Eliminate
keep pouring temperature at last flasksreject
and die casting (No Re-Casting) Zero Re-casting Zero Re-casting Simulation Eng Suranto Rio K.
Trial &
Defect In Process 2.2. Increase Quality Achievement improve furnaceB.4.
RCSCO2
2.2.1. reduction
condition
Continous Improvement Next Process Defect Reduction by: Defect Next process : Process Die design Evaluation
6,63676994 Study Prepare Implementation
1TR 2TR Cams Defect Next Process CO2 B.4.1. CO2 reduction
Energy saving through reduce unnecessary process (non Production) 0.053 Ton / Unit 0.048 Ton / Unit M/T A.Kohar Toto W.
0,1342.2.1.1 Achieve uniform solidification by gating system Eng Suranto Rio K.
8,0 4
6,23919564 0,133 0,50% 0,40%
6,0 4,405493531,98558924 4,76029130 1TR 2TR Cams
4,0 4,717136582,74912631 8,0 2 2,94720717 2.2.2. Continous Improvement In Process Defectdesign
Reduction by:
0,132 improvement Defect In process :
%

5 1,3 6,02,03
1,96164966 6

(Ton/unit)
2,0 0,97617254
0,943460810,98005933
1
0,67630788
0,94381615
0,59577735
0,44599573 0,5
0,980535631,71047572
4,00,71 8 5 3,26 0,132 0,131 Tuning mixing process Improve squeeze
Portable & jolt
burner process
installation Furnace RCS improvement
%

0,74 1,006540220,64907711 2.2.1.2optimum

Eliminatemold
excess
2.2.2.1 Improve 0,67
mold quality by achieve 0,13gas0,13
source while pouring by Eng Suranto Rio K. Eng Suranto Rio K.
9 0,4 1,5
0,0 7
7 5
4 1
4 2,00,58
3,29701033
6 8
7
0,97165511
1,32647494
4 0,4 1,54
FY17
FY16 FY18
FY17 FY19
FY18 FY20
FY19 0,0 BM 8 2,04327535 7
3
0,5
0,6 1,05 0,130 0,55% 0,41%
Repair
FY17
FY16
29,5668246
FY18
FY17 FY19
FY18 FY20
FY19 and best water addition keep
hardness BM vs CBpouring
ratio temperature at last flasks and
30,0 11,6021680
1TR
9,230485417,50129985
4
2TR 15,1 Defect In Process 0,128 improve furnace RCS condition
6,63676994 FY17
FY 16 FY18
FY 17 FY19
FY 18 FY20
FY 19 BM
4 1 1TR 2TR Cams
2 6,5 14,4668246
8,0 4
5,238299063,57236084
10,0 5,23216804
%

6,37 3,99218634 3,92893900 3 6,0 4,405493531,98558924 Kick off Quality

Board
6 5 3,5 4,0 44,717136582,74912631 2 QUALITY
2.2.2. Continous Improvement In Process Defect Reduction by: Defect In process : Build In Quality Campaign
%

3 6 7 5 2,03

2.1 Meningkatkan pencapaian quality

0,97617254 0,94381615 1,3 Visualization
-10,0 FY16 FY17 FY18 FY19 2,0 BM0,943460810,98005933
1
0,676307880,59577735
0,44599573 0,5 0,71
0,74 Tuning mixing process Improve squeeze &Socialization
jolt process PDCA
FY17 FY18 FY19 FY20 0,0 7
7 5
4
9
1
4
0,4
0,4 0,58 2.2.2.1
2.1. Zero Out Improve
Flow moldCustomer
& Claim quality by achieve 2.1.1.
optimum mold build in quality in each process (Outflow)
Review Zero Outflow Zero Outflow Eng Suranto Rio K. Eng Suranto Rio K.
FY17
FY16 FY18
FY17 FY19
FY18 FY20
FY19 BM 0,55% 0,41%
Repair 29,5668246 hardness and best water addition vs CB ratio
3 PRODUCTIVITY 30,0 11,6021680 4 2.1.2 Eliminate reject die casting (No Re-Casting) Zero Re-casting Zero Re-casting Simulation Eng Suranto Rio K.
1TR
9,230485417,50129985 2TR 15,1 Trial &
3.1. Smooth OEE 92.6%, Senmon Hozen Achieve 4 Gold3.1.1.
1LevelProductivity
2
5,238299063,57236084 6,5 OEE
14,4668246 2.2. Increase Quality Achievement 2.2.1. Continous93,0% 93,1%Defect Reduction by:
Improvement Next Process Defect Next process
Evaluation : M/T A.Kohar Toto W. Process Die design Evaluation
10,0 5,23216804
%

6,37 3,99218634 3,92893900 3 Prepare Study

3.1.1.1. Avability Defect Next Process Trainning
6 5 3,5 4
2.2.1.1 95,90% 96,00%
Achieve uniform solidification by gating system M/T A.Kohar Toto W. Eng Suranto Rio K.

2.1 Menghilangkan NG Komposisi proses melting - Pouring

3 6 7 Evaluation
6,23919564 0,50% 0,40%
100% -10,0 FY16 FY17 FY18 FY19 BM 4,76029130 1TR 2TR Cams
Trainning
0.922 FY17 FY18 3.1.1.2.
FY19 Performance efficiency
FY20 8,0 2 2,94720717 98,00%improvement
design 98,00% Prepare M/T A.Kohar Toto W.
6
6,0 1,961649661,71047572
0.91 0.912 0.915 0.91 4,0 0,98053563
8 5 3,26
Portable burner installation Furnace RCS improvement
%

1,006540220,64907711 2.2.1.2 99,00%

Eliminate excess gas source while pouring by Eng Suranto Rio K.
3 PRODUCTIVITY 3.1.1.3. Rate of Quality 2,0 3,29701033
6 8
7
2,04327535
0,97165511
1,32647494
4
1,5
0,4
0,67
1,54 99,00% M/T A.Kohar Toto W.
0,0 8 7 0,5
0,6 1,05
3 keep pouring temperature at last flasks
90% 3.1. Smooth OEE 92.6%, Senmon Hozen Achieve Gold
3.1.1. FY17
LevelProductivity
FY16 FY18 OEE
FY17 FY19
FY18 FY20
FY19 BM 93,0%and 93,1% Evaluation M/T A.Kohar Toto W.
3.1.1.1.Defect In Process
Avability improve furnace RCS condition 95,90% 96,00% Prepare Trainning Evaluation M/T A.Kohar Toto W.
6,63676994
1TR 2TR Cams
100% 8,0 4 Prepare Trainning
0.915 0.922 6,0 3.1.1.2. Performance
1,98558924 efficiency
4,40549353 98,00% 98,00% M/T A.Kohar Toto W.

M. Mujiono
80% 0.91 0.912 0.91 4,0 4,717136582,74912631 2.2.2. Continous Improvement In Process Defect99,00%
Reduction by: Defect In process :
%

2,03
3.1.1.3.
2,0 0,97617254 Rate
0,943460810,98005933
1 of 5Quality1,3
0,94381615
0,59577735
0,67630788
0,44599573 0,71
99,00% M/T
Tuning mixing process
A.Kohar Toto W.
Improve squeeze & jolt process
Ave FY16FY17FY17 FY18FY18 FY19FY19 BM
FY20 0,0 7 5 9 0,5
0,4
0,4 0,74
0,58 2.2.2.1 Improve mold quality by achieve optimum mold Eng Suranto Rio K.
7 4 1
4
90% FY17
FY16 FY18
FY17 FY19
FY18 FY20
FY19 BM 0,55% 0,41%
29,5668246 hardness and best water addition vsBenchmark
CB ratio Sosialization Implementation
3.2. Slim PEFF Casting 3.2.1. Smooth Implementation Casting PEFF
30,0 11,6021680
Repair
4
PEFF 0,986 PEFF 1,0 Prod Suranto Saripudin
1TR
9,230485417,50129985 2TR 15,1
1,1 1,05 3.2.2. Reduce Temachi through SW Kaizen4 N/A Temachi Max 3% Theme 1 Theme 2 Theme 3 Theme 4 Prod Suranto Saripudin

Section Head Diepress

1,1 0,966 1 1 1 2 6,5 14,4668246
80% 6,37 5,23829906
10,0 5,23216804
3,992186343,57236084
%

3,92893900 3 Robot Manufacture Fabrication

0,9 3.2.3.
Ave FY16FY17 Eliminate
FY17 FY18 FY18 FY19Muda job
BMthrough simple3kaizen 6
FY19 FY20 6 5
7
3,5 4 N/A 4 Post Eng Suranto Saripudin
-10,0 FY16 FY17 FY18 FY19 BM
0,7 3.2.4. Smooth Implementation 4S Activity base on
FY17 FY183 Pilar
FY19 FY20 50% Gold 100% Gold Audit Audit Audit Audit Prod Suranto Mujiono
PEFF

3.2. Slim PEFF Casting 3.2.1. Smooth Implementation Casting PEFF PEFF 0,986 PEFF 1,0 Benchmark
Trainning
Sosialization
Implementation at Casting
Implementation
Prod Suranto Saripudin
0,5 3.2.5. Create Master 3 TPS at Casting
PRODUCTIVITY N/A 1MP Prod Suranto Roni B.
1,1 1,1 1,05 3.2.2. Reduce Temachi through SW Kaizen N/A Temachi Max 3% Theme 1 Theme 2 Theme 3 Theme 4 Prod Suranto Saripudin
 Step 0-2:Rencana Activitas
SCHEDULE ACTIVITAS CL DAN QCC GRESSMEN 2020/2021
YEAR 2020/2021
No. ACTIVITY PIC
Apr Mei Jun Jul Agust Sept
1 JUDGEMENT ASSESSMENT GROUP (CHECK) CL

2 ANALISIS PROBLEM GROUP CL

CL
3 MENDEVELOPMENT MEMBER (APLIKASI)

4
Activitas QCC :
UPDATE SKILL (MONITORING) CL

THEME ACTIVITY
STEP 0-1 1. 14 Pertemuan meeting
PEMILIHAN THEMA Irfan

Fadil

2. Selama 6 bulan ( total hari kerja)

STEP 0-2 RENCANA ACTIVITAS

STEP 1 KLARIFIKASI MASLAAH Teguh

STEP 2 ANALISA KONDISI YANG ADA Teguh

STEP 3 PENETAPAN TARGET Basith

STEP 4 ANALISA SEBAB AKIBAT Supri

STEP 5 RENCANA PENANGGULANGAN Basith

STEP 6 PENANGGULANGAN Supri

STEP 7 EVALUASI HASIL Sulis

STEP 8 STANDARISASI DAN TINDAK LANJUT Ekwan

= PLAN = ACTUAL
 Step1 : Klarifikasi Masalah
NG
KPI Grafik NG Komposisi
Komposisi
GAP Pareto NG Komposisi Pouring
Pouring Berdasarkan Jenis Material Molten metal
Q Jan-Mar 21
12
Pouring Actual :
14
14
100%
100

14
95%

71%
10 N : 14 Kasus Sect. Head 80

8 Kasus M. Mujiono 11 Nn =
=1.41
14
Std : 0 Kasus
5 6 10 60
6

4 3 14 9
Material 40

2 Avg : 4 Kasus Kasus 5

FCD
3 20

0 1

Ideal : 0 D/U
0 0

Kasus Jan Feb Mar Kasus FCD TGC TNC

Pareto NG komposisi Pouring FCD Pareto NG Magnesium

Berdasarkan Element Material Kimia berdasarkan Range Thema :
100 % (0,040 – 0,060)
Menghilangkan
90%
10 100 100%
80% 100
70% 90 6

9
60%
N = 10
80
70
5
6 84% 80
n = 1.41
NG Komposisi Pouring
Pada Material FCD
60
N=6 60
7
6 n = 0.91 50
4

Ketika Magnesium
40 40
5 Magnesium 30
Rendah
2 20
20
2 1
1 1 1
10
0
0
0
Tinggi
0 Rendah
0 Rendah
Kasus Magnesium Silicon Carbon CU Ni Kasus < 0,040 > 0,060
 Pejelasan NG Magnesium
Knowledge Magnesium berfungsi sebagai pelarut molten metal untuk
Kenapa membentuk keuletan dalam benda kerja
Magnesium Ada beberapa
bisa NG? Factor….
Faktor – faktor yang mempengaruhi Magnesium rendah :
1. Add. Material cairan (Sb, Lmc.. dsb..)
2. Pemanasan Berlebih (Superheating)
3. Penahanan cairan setelah Mg Treatment

Flow Proses Magnesium Treatment

Penimbangan Memasukkan Pencampuran Mgenesium Proses penahanan cairan Penuangan Cairan ke
Magnesium Magnesium Treatment dengan cairan setelah Mg Treatment dalam cetakan

Penimbangan Charging Mg Delivery Ladle

Tapping (proses penguapan Mg) Pouring
Magnesium Treatment
 Step 2 : Analisa Kondisi yang Ada
Charging PIC : Fadil + Teguh
Tapping Delivery Ladle Pouring
Mg Treatment Tanggal : 27 – 30 Mei 2021

Proses Penambahan Magnesium Treatment ke dalam ladle Ilustrasi Problem

Op

Material
plat baja

Ladle
Taamoak
samping

Lokasi FC
Mg Tidak (Free)
Tertutupl
plat baja

Mg

Core Problem 1 :
Material Mg Treatment jatuh menyebar di ladle
 Step 2 : Analisa Kondisi yang Ada
Penambahan Penuangan PIC : Irfan + Supri
TAPPING Delivery Ladle
Mg Treatment ke cetakan Tanggal : 2 – 5 Mei 2021

Penuangan Cairan dari Furnace ke Ladle Ilustrasi Problem

Temp. Furnace
1500 °

Cairan
Molten metal

Ladle

Magnesium

Lokasi
Free

Core Problem 2 :
Cairan awal jatuh di Lokasi Magnesium treatment
 Step 2 : Analisa Kondisi yang Ada
Penambahan Penuangan PIC : Ekwan + Suwanto
TAPPING Delivery Ladle
Mg Treatment ke cetakan Tanggal : 3 ~ 7 mei 2021

Proses Delivery ladle (Tapping – Siap Pouring) Ilustrasi problem 3

Pengatur waktu delivery ladle

14’51’’

Waktu
Delivery Over

Ideal : Waktu delivery 10 – 12 menit

Core Problem 3 :
Waktu delivery ladle Over (Range 14 - 15 menit)
 Step 2 : Analisa Kondisi yang Ada
Penambahan Penuangan PIC : Ekwan + Suwanto
TAPPING Delivery Ladle
Mg Treatment ke cetakan Tanggal : 3 ~ 7 mei 2021

Penuangan cairan ke dalam cetakan Ilustrasi Problem

dengan material tambahan Pengatur waktu pouring

> 60 detik

Ideal : Waktu Pouring < 60 detik

Core Problem 4 :
Waktu Pouring Over > 60 detik
 Step 2 : Analisa Kondisi yang Ada

Sub Thema Berdasarkan Kasus :

Menghilangkan NG Komposisi Pouring pada Material
FCD Ketika Magnesium rendah Selama :

1. Delivery Ladle Over Range 14 -15 menit (3 Kasus)

2. Material Mg Treatment Jatuh menyebar di ladle (2 Kasus)
3. Cairan awal jatuh Di lokasi magnesium (2 kasus)
4. Waktu Pouring Over > 60 detik (1 Kasus)
 Step 3 :Penetapan Target

Get Member’s Comitment

Dengan Aktifitas QCC Mari kita ciptakan

tempat kerja yang menyenangkan
 Aktifitas Circle Leader
Strategi 3 : Membuat Inovasi Training Terkait Aktifitas Meeting
A. Problem B. Action
Proses Meeting terkendala pertemuan 1. Meeting Via Ms. team

Proses Meeting sebelum

Covid-19
Tolong Batasi pertemuan
meeting, namun
activitas tetap berjalan
dengan menjaga
prokes..!!

• Selama Pandemi Meeting

QCC via Ms. team

Strategi :
1. Proses Meeting Online (Via Ms. Teams)
2. Proses Meeting Online (Via Aplikasi Meeting Gressmen)
3. Proses Meeting Outdoor (15 Menit 2x Pertemuan)
 Aktifitas Circle Leader

2. Meeting Via Aplikasi 3. Meeting Outdoor Dengan Protokol Kesehatan (Durasi 15’) 2x Pertemuan

Aplikasi Meeting

Meeting diruang
terbuka

Lokaasi Meeting :

• Café
• Gajebo
• Dan lapangan

Result : Proses Meeting berjalan 100%, On Schedule

 Step 4 : Analisa Sebab Akibat

4 (Empat) Root Cause

5m

Jarak penambahan 4 Lubang corong add.

1 Delivery ladle Tidak 2 Ladle Bergerak 3 material Mg Treatment material hanya
beraturan 15° saat tapping jauh (4 meter) terbuka 50 %
 Step 5 : Rencana Penanggulangan
4 Rencana Penanggulangan

2 Instal
3 Instal Stopper 4 stopper
Re-layout area pengunci ladle
1
Instal sutter Mg Sliding gate saat
Delivery ladle saat tapping
Treatment pouring
Implamentasi Training Kaizen
Mr. Supri Kaizen 1 Kaizen 2 Kaizen 4
Kaizen 3

Ayo.. Semangat ..
Kamu jadi
leader ya..
di kaizen!!

Mr. Teguh Mr. Sulis Mr. Ekwan Mr. Basith

 Step 6 : Penanggulangan

1 KAIZEN PIC Supporting

Proses delivery ladle tidak Beraturan

2,2
menit

3,6
menit

Jalur Delivery across (menyilang) Jalur Delivery Straight (Lurus)

 Step 6 : Penanggulangan

2 KAIZEN PIC Supporting

Penambahan material Mg Treatment jauh 4 meter

Jarak Jatuhnya
Jarak Jatuhnya
material Mg
material Mg
Treatment 2 m
Treatment 4 m

4M

2M
 Step 6 : Penanggulangan

BEFORE KAIZEN 3
 Step 6 : Penanggulangan
AFTER KAIZEN 3
 Step 6 : Penanggulangan

BEFORE KAIZEN 4
 Step 6 : Penanggulangan
AFTER KAIZEN 4
 Step 6 : Penanggulangan

PDCA 1

Instal Cover

Spatter Pouring
 Step 6 : Penanggulangan

Inovasi
Improvement 1

Result :
Step 7 : Evaluasi Hasil

Kaizen 1

Kaizen 2
Kaizen 3
Kaizen 4

42
 Step 7 : Evaluasi Hasil

S afety
Kualitas Graphit OK..
Waktu Proses Pouring
uality
TERJAMIN
Tidak ada proses Recycle die karna Kontribusi dari
roductivity NG Komposisi Magnesium Kaizen Zone melting & Pouring 5,1%

ost
 Activitas Circle Leader

Mengadakan Activitas Kebersamaan K-Forest Edu Sentul, Bogor

Video Kebersamaan

Result : Kerjasama team meningkat member bersemangat dalam bekerja

 Step 7 : Evaluasi Hasil
BEFORE SUMBU X SUMBU Y
AFTER SUMBU X SUMBU Y

AVE SUMBU X

AVE SUMBU Y

AVE SUMBU X

AVE SUMBU Y
LEADERSHIP

LEADERSHIP
ZONE

ZONE
MULTISKILL

MULTISKILL
KOMUNIKASI

KOMUNIKASI
ASSESSMENT ASSESSMENT

TEAMWORK

TEAMWORK
MOTIVASI

MOTIVASI
7 TOOLS

7 TOOLS
MEETING
KAIZEN

MEETING
KAIZEN
SAFETY
8 STEP

SAFETY
8 STEP
MEMBER MEMBER
GRAVITY GRAVITY
SUWANTO( CL ) 4.0 5.0 5.0 5.0 5.0 4.8 A 5.0 5.0 5.0 5.0 5.0 5.0 SUWANTO( CL ) 4.0 5.0 5.0 5.0 5.0 4.8 A 5.0 5.0 5.0 5.0 5.0 5.0
M. TEGUH .T( TL ) 4.0 4.0 4.0 5.0 3.0 4.0 B 4.0 4.0 4.0 4.0 4.0 4.0 M. TEGUH .T ( TL ) 4.0 4.0 4.0 5.0 3.0 4.0 A 4.2 5.0 4.0 4.0 4.0 4.0
SUPRIYANTO( NTL) 4.0 4.0 4.0 5.0 1.0 3.6 B 4.0 4.0 4.0 4.0 4.0 4.0 SUPRIYANTO. ( NTL ) 4.0 4.0 4.0 5.0 3.0 4.0 A 4.2 5.0 4.0 4.0 4.0 4.0
A. BASIT 2.0 3.0 3.0 3.0 5.0 3.2 C 3.6 4.0 4.0 3.0 4.0 3.0 A. BASIT 3.0 3.0 3.0 3.0 5.0 3.4 B 3.8 5.0 4.0 3.0 4.0 3.0
SULISDIYANTO 2.0 3.0 3.0 3.0 3.0 2.8 C 2.6 1.0 3.0 3.0 3.0 3.0 SULISDIYANTO 3.0 3.0 3.0 3.0 3.0 3.0 B 3.2 4.0 3.0 3.0 3.0 3.0
EKWAN P. 2.0 3.0 3.0 3.0 3.0 2.8 C 2.2 1.0 3.0 2.0 2.0 3.0 EKWAN P. 3.0 3.0 3.0 3.0 3.0 3.0 B 2.8 4.0 3.0 2.0 2.0 3.0
IRFAN B. 1.0 2.0 2.0 2.0 1.0 1.6 D 2.0 1.0 3.0 2.0 1.0 3.0 IRFAN B. 3.0 2.0 2.0 2.0 3.0 2.4 C 2.8 4.0 3.0 2.0 2.0 3.0
FADIL 1.0 1.0 1.0 1.0 1.0 1.0 D 1.8 1.0 3.0 1.0 2.0 2.0 FADIL 3.0 2.0 2.0 2.0 3.0 2.4 C 2.4 3.0 3.0 2.0 2.0 2.0
AVE GROUP 2.5 3.1 3.1 3.4 2.8 3.0 3.2 2.6 3.6 3.0 2.6 3.4
Result : Level Assessment naik X : 3,4
AVE GROUP
dan Y : 3,6
3.4 3.3 3.3 3.5 3.5 3.4 3.6 4.4 3.6 3.1 3.3 3.4

Before Before A Assessment Member Assessment Group

After 100
60% 50
E B
After 0

68% Sumbu X
D C

A
Before
X=3,0
Before Y=3,2
100
64% E 50
B
After 0

72% Sumbu Y
D C
 STEP 8. STANDARISASI
PT. TOYOTA MOTOR MFG
SIGNED
INDONESIA
PLANT 2 WELDING
PRODUCTION
STANDARISASI Mujiono Suwanto Suwanto Mislan Tb rahman Zaenal

NO ITEM STANDARD KEY POINT ILUSTRASI

SOSIALISASI
PELATIHAN

1
Stoper ladle saat - Masuk ke lobang - Stoper tidak bengkok
tapping ladle - Engsel tidak macet
M. Teguh T

Instal Karakuri
- Shuter bisa - Shuter bisa digerakkan Supriyanto

2 Shuter Mg
memutar - Engsel tidak rusak
treatment
A Basit

- Ladle mentok
gawang Sulis

Re-layout area - Waktu fadding <

3 - Jarak dasar ladle
Slag remover 15 menit
dan lantai
Ekwan

<100mm

Irfan

Instal karakuri Tuas naik turun

4 - Sliding tidak macet
streaming LMC dengan lancar
Fadil
 Visit Management

Sosialisasi dan Showing Improvement by Management

 Tindak lanjut

Matrix Pemilihan Thema

Evaluation Item Total
No Problem Urgensi Durasi Dampak Cost
Performa kerja Point
thema thema problem benefit

14
Menghilangkan 1. Urgent 1. 12 bulan 1. Defect 1. 100 juta 1. 25 %
1 2. Sedang 2. 9 bulan 2.Complaint 2. 50 juta 2. 50 %
Defect Terak (Zanza) 3. Sangat Urgent 3. 6 Bulan 3. Reject 3. 10 juta 3. 100 %

1. Urgent
Menurunkan 2. Sedang 1.12 bulan 1. Defect 1. 100 juta 1. 25 %
2 Defect 3. Sangat 2. 9 bulan 2. Complaint 2. 50 juta 2. 50 % 11
over cutting (coak) Urgent 3. 6 Bulan 3. Reject 3. 10 juta 3. 100 %

1. Urgent
2. Sedang 1.12 bulan 1. Defect 1. 100 juta 1. 25 %
Menurunkan
3 Pemakaian material melting
3. Sangat 2. 9 bulan 2. Complaint 2. 50 juta 2. 50 %
v 9
Urgent 3. 6 Bulan 3. Reject 3. 10 juta 3. 100 %

THEMA :
Menghilangkan
Defect Terak (Zanza) di Line Melting
48
49