1. 1/15 GEMBA MANAGEMENT S tandardization & Quality Assurance Policy Management Cross- Functional Management Daily Management Suggestion System Quality Control Circle 5 S

2. 2/15 Gemba Management in Company Management Maintain and implement the current system (Routine work) Continuous Improvement (KAIZEN) TOP MANAGEMENT MIDDLE MANAGEMENT SUPERVISOR FOREMAN & OPERATOR GKM 3S 5R Innovation

3. 3/15 5R IMPLEMENTATION WAY TO DEVELOP WORLD CLASS COMPANY CULTURE 5S Seiri Seiton Seiso Seiketsu Shitsuke5C Clear-out Classify Cleaning Conformity Custom 5R Ringkas Rapi Resik Rawat Rajin5P Pemilahan Penataan Pembersihan Pemantapan Pembiasaan

4. 4/15 5R IMPLEMENTATION OBJECTIVES To create a comfortable workplace and interesting job To train employee independently organize his/her work To enforce discipline is using standard To create “Visual Factory” Create positive image upon customer view

5. 5/15 EFFECT ON 5R IMPLEMENTATION Minimize the potention of: –Accident –Breakdown –Cost –Defect Increase efficiency and work motivation A ready organization for transformation in direction of Top management strategy

6. 6/15 TRANSFORMATION: BEHAVIOR & WORKPLACE CONDITION Workplace BehaviorAttitude BehaviorAttitudeCulture 5R IMPLEMENTATION Customs ( 3 principles : Consistency, Continuity & Simplicity) TRAINING

7. 7/15 SUGGESTION SYSTEM SUGGESTION SYSTEM Definition Management system that involves every customer in improving quality through individual suggestion for improvement

8. 8/15 SS DEVELOPMENT IN JAPAN (1984) THE BIG TEN GROUP IN SS IMPLEMENTATION Matsushita (Panasonic)6.58 million Hitachi4.65 million Mazda3.06 million Toyota2.15 million Nippondenso1.43 million Mitsubishi Motors1.12 million Nissan Motor1.07 million Aisin Seiki 0.97 million Bridgestone Tire0.95 million Japan National Railway0.78 million

9. 9/15 SS IN TOYOTA MOTOR CORP. (1984) Number of suggestion :2.1 million Number of suggestion/ employee :40 Participation level:95% Acceptance level:95%

10. 10/15 COMPARATIVE STUDY ON SS DEVELOPMENT IN AMERICA AND JAPAN (1989) USAJapan Number of people implementing SS 282 666 Number of employee involved 8.642.269 1.646.960 Number of suggestion accepted996.694 60.343.937 Number of suggestion /100 employee 12 3.664 Number of employee suggest /100 employee 9 75 Adoption rate 32% 87% Rerata award/adoption $602.15 $2.20 Rerata economy/adoption $6.114 $110 Economy/ 100 employee $22.825 $365.656

11. 11/15 THE DIFFERENCE OF SS WEST VERSION AND JAPAN VERSION West (America) Emphasize on economical output( great ideas) Extremely put emphasis on Financial incentive Personal motivation SS Committee responsibility Japan Emphasize on participation (small ideas) Psychological Incentive (pengakuan dan aktualisasi diri) Personal motivation and group Top management responsibility

12. 12/15 SS OBJECTIVES IN MANAGEMENT Suggestion system ideas can be directed for: Ideas to increase sales –improve servicing, product image, product selection, exhibition method, etc Ideas to lower cost – efficient work, reduce non-quality product; overtime work, wastes; inconsistency; etc

13. 13/15 SS IMPLEMENTATION STRATEGY AND MECHANISM Suggestio n system Mechanism Strategy System Organization Regulation Reward System Standard Evaluation Suggestion Form Education and Training Campaign Promotion activity Motivation encouragement Coaching and Counseling

14. 14/15 QUALITY CONTROL CIRCLE QUALITY CONTROL CIRCLE Definition Group consist of operators with specific job who meet together periodically to discuss and solve problems and the job environment with focus on improving quality using quality control system

15. 15/15 QUALITY CONTROL CIRCLE OBJECTIVES Improve problem- solving ability Increase involvement of employee in problem solving Promote teamwork in the group Increase awareness of problem prevention Increase employee motivation Increase communication in the group Improve Top-Bottom relationship improve quality