Lampiran 1. Struktur organisasi perusahaan

Transkripsi

1 . LAMPIRAN 59

2 Lampiran 1. Struktur organisasi perusahaan 60

3 Lampiran 2. Sturktur organisasi divisi Purchasing 61

4 Lampiran 3. Kegiatan yang dilakukan 62

5 Lampiran 4. A3 report 63

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7 Lampiran 5. Time Sheet Study Time study Sheet Kegiatan Operator Nama subjek : code : Jenis kelamin : Tinggi /berat : cm / kg Usia : tahun Hari/tanggal : Jam : Cuaca : suhu : kebisingan : Kegiatan : 65

8 Lampiran 6. Grafik denyut jantung saat kalibrasi step test 66

9 Lampiran 7. Grafik persamaan WEC st dan IRHR 67

10 Lampiran 8. Grafik HR kerja operator crankcase 68

11 Lampiran 8 (lanjutan). Grafik HR kerja operator crankcase 69

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27 PT. TOYOTA MOTOR MANUFACTURING INDONESIA PURCHASING DIVISION PURCHASING NO.1 DEPARTEMENT Theme: Cost Reduction Activity Approved Checked Prepared I. PERSONAL DETAIL Date : 23 / June / 2011 Sheet Number A. Hatmadji Wahyu SP Aqmarina Indra Name : Aqmarina Indra Education : S1 Institut Pertanian Bogor(Teknik Mesin dan Biosistem) Departemen : Purchasing no.1 I. BACKGROUND Internship Period : 21 March - 20 Jun 2011 Division : Purchasing Vehicle sales and production in domestic market will reach 1 million unit/years in At the same time, competition among Car Brands is getting more severe. Because of that Toyota keep trying to improvement, yet price of material often has increase. So division Purchasing make a plan to get cost reduction to balance impact cost up due to material cost increasing (maintain competitives cost) II. Analysis Toyota Bisnis Practices Step 1 Clarify the Problem Step 2. Breakdown Analysis < Ultimate Goal > < By raw material> < by supplier > < Point of occurance > to be the best cost in Asia region Contribution < Ideal Situation > Achieve 2011 cost reduction : % Rp 105,203 B < Problem > Unachieve cost reeduction % Rp 21,350 B < Break Down> Interior and electrical section % (- Rp 33, 822 B) Body and exterior section % (+ Rp 12,515 B) SEAT 13 % RESIN 6% TBINA 0.00% SGT: % (-Rp 3,605 B) IR3 : -0.52% (-Rp 791 B) AOP : % (-168 B) DLD :1.29 % (Rp 1,196 B) ICH: 0.99 % (Rp 745 ) DWA : 0.00% material cost process cost FOH depreciation Price approval Benchmarking Activity GENBA < Problem to Tackle > Buyer still no have actual information about material and process cost evaluation Quatation received RFQ Step 3 Target Setting < Current Situation > Cost reduction achievement still : % Rp 83,853 B (non-cpp) Chassis and engine section % (- Rp 623 B) Service and component section % (+ Rp 580 B) RUBBER 4 % FTR: %(-Rp 914 B) IRC: %(- Rp 398 B) ITG:- 0.5 % (-Rp 271 B) IKP : % < Machine > < Methode > < Material > < Man > Step 7 Evaluation process and result 1. Langkah yang disarankan a. Analisis biaya i.cari biaya apa yang terbesar diantara part yang ada? ii.bandingkan dengan part dari supplier lain yang sejenis b. Cari fungsi asli dari part tersebut Dengan diketahuinya fungsi asli part dapat ditentukan raw material yang tepat i. Apakah mungkin mengganti raw material ke grade yang lebih rendah (lebih murah) ii. Apakah mungkin dikurangi ketebalan (thickness ) part c. Pecahkan masalah yang ada berdasarkan aspek-aspek yang mungkin Seperti design, metode manufacturing, tenaga kerja, biaya mold, dan lain-lain d. Rencana perbaikan i. Pemeriksaan untuk CR terhadap semua aspek yang mungkin termasuk material, bentuk. ii. Kembangkan teknologi atau teknik baru e. Evaluasi Adakan evaluasi mengenai hubungan antara biaya dan teknik, kualitas, produksi, pasar, dan lain-lain 2. Cara untuk mengembangkan ide a. Benchmarking atau studi banding b. Diskusi c. Genchi Genbutsu 3. Proses cost a. Cek berapa mesin tonnage yang sebaiknya digunakan b. Cek berapa lama mesin tersebut sudah digunakan. Apabila bukan mesin baru bisa negosiasikan harganya. c. Cek cycle time dengan cara mengambil beberapa sample part yang sedang dibuat d. Cek apakah cycle time atau mesin tonnage yang digunakan dapat diganti e. Apakah mungkin coating suatu part tersebut dihilangkan Before improvement no information about material no information about process make a part no standarization to find CR After countermeasures there is a information or guidance about material (specification material, consumption resin material, and source raw material) there is a information or guidance about process (steptomakepartwith to part injection, how to determine machine tonnage, cycle time, and cost) there is a standarisasi Evaluation result All data about material, process, cost, and how to get CR already arrange OTHERS 1 % NITTO :0.00 % AMT : 0.00 % Activity Dimana Kapan Bagaimana Evaluasi reading book study material (resin TMMIN Apr meet supplier material) meet engineering study process injection Supplier 4-Apr Genba TMMIN bertemu engineering study plating 4Apr Supplier 20May Genba Genba (process, material) study how to determine machine tonage Supplier Supplier 24Maret 31Maret 11-May Genba meet supplier, discuss with supplier, departemen head and section head meet supplier, discuss study calculation cost TMMIN May- June with supplier, departemen head and section head meet supplier, discuss study plating cost Supplier 9-Jun with supplier, departemen head and section head Step 6 See Countermeasures Through Machine not influence to get information Masalah yang ditangani All actual information about process cost, material cost, and to find CR, kadai already checked, arrange in one manual book item man, metode data that affect CR not enough (raw data) Buyer have many work and don't have time to arrange Root Cause no actual methode to get information that influence CR < Countermeasures > Countermeasures no collection data which content with CR no manual book < Root Cause > study about part in vehicle study about resin material Identification resin no training material consumption in material parts (no study about process manual (process injection and book) plating) study about calculationand determine machine tonnage study about cost Step 5 Develop Countermeasures buyer experience is low no training for new buyer Schedule Apr May June I II III IV V I II III IV V I II III Step 4 Root Cause Analysis