QUALITY COMPARISON REPORT OF ASSEMBLY SECTION

(2007)
Part Name : Mirror Assy, Inside RR View Model : D99B (Prism)
Customer No. : 87810 - BZ080 Customer : PT. ASTRA DAIHATSU MOTOR
Toyo No. : 8549 - 01
NO. NG ITEM JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL NG RATIO
1 MIRROR (Bintik) 0 1 2 0 1 12 0 8 5 0 0 29 0.25%
MIRROR
2
(Marking) 0 0 0 68 10 0 0 0 0 0 0 78 0.66%
3 LEVER 0 0 45 33 31 6 0 35 0 0 3 153 1.30%
4 STAY 0 4 4 1 6 3 0 9 0 0 4 31 0.26%
5 Mirror ( Garis) 0 6 0 15 8 18 0 17 12 3 1 80 0.68%
Mirror
6 0 1 0 0 0 3 0 4 3 0 0 11 0.09%
( Gompal)
Mirror
7
( Noda) 0 0 0 5 1 15 0 0 0 0 0 21 0.18%
8 Bracket 0 0 0 11 35 8 0 23 0 0 0 77 0.66%
9 Housing 0 0 0 1 0 2 0 0 0 0 3 6 0.05%
10 Noise 0 0 0 0 0 200 0 0 2 13 0 215 1.83%
Torque 0 0 0 0 0 0 0 0 0 37 20 57 0.49%
TOTAL NG 0 12 51 134 92 267 0 96 22 53 31 758 6.45%
TOTAL OK 0 901 1,291 1,230 1,230 1,140 0 1,200 1,202 936 1,856 10,986 93.55%
TOTAL
PRODUCTION
0 913 1,342 1,364 1,322 1,407 0 1,296 1,224 989 1,887 11,744

% NG #DIV/0! 1.31% 3.80% 9.82% 6.96% 18.98% #DIV/0! 7.41% 1.80% 5.36% 1.64%
% OK #DIV/0! 98.69% 96.20% 90.18% 93.04% 81.02% #DIV/0! 92.59% 98.20% 94.64% 98.36%

QUALITY COMPARISSON TABLE

100% 99% 98% 98%
96% 95%
93% 93%
90%
90%
81%
80%

70%

60%
RATIO

50% Row 23
40% Row 22
30%

20% 19%
Date : Desember 07
10% Approved Checked Prepared
10% 7% 7%
4% 5%
1% 2% 2%
0%
Column Column Column Column Column Column Column I Column Column Column Column Column
C D E F G H J K L M N
MONTH
PT. PROGRESS TOYO ( INDONESIA )
Column Column Column Column Column Column Column I Column Column Column Column Column
C D E F G H J K L M N
MONTH

PT. PROGRESS TOYO ( INDONESIA )

 QUALITY COMPARISON REPORT OF ASSEMBLY SECTION
(2007)
Part Name : Mirror Assy, Inside RR View Model : D99B (Prism)
Customer No. : 87810 - BZ080 Customer : PT. ASTRA DAIHATSU MOTOR
Toyo No. : 8549 - 01
NO. NG ITEM JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL NG RATIO
1 MIRROR (Bintik) 0 0 0.00%
MIRROR
2
(Marking) 0 0 0.00%
3 LEVER 0 0 0.00%
4 STAY 0 0 0.00%
5 Mirror ( Garis) 3 3 0.30%
Mirror
6 0 0 0.00%
( Gompal)
Mirror
7
( Noda) 0 0 0.00%
8 Bracket 0 0 0.00%
9 Housing 0 0 0.00%
10 Noise 13 13 1.31%
11 Torque 37 37 3.74%
TOTAL NG 53 53 5.36%
TOTAL OK 936 936 94.64%
TOTAL
PRODUCTION
989 989

% NG 5.36%
% OK 94.64%

QUALITY COMPARISSON TABLE

100%
95%
90%

80%

70%

60%
RATIO

50% Row 23
40% Row 22
30%

20% Date : Desember 07

10% Approved Checked Prepared

5%

0%
Column Column Column Column Column Column Column I Column Column Column Column Column
C D E F G H J K L M N
MONTH
PT. PROGRESS TOYO ( INDONESIA )
Column Column Column Column Column Column Column I Column Column Column Column Column
C D E F G H J K L M N
MONTH

PT. PROGRESS TOYO ( INDONESIA )

 QUALITY COMPARISON REPORT OF ASSEMBLY SECTION
(2007)
Part Name : Mirror Assy, Inside RR View Model : D99B (Prism)
Customer No. : 87810 - BZ080 Customer : PT. ASTRA DAIHATSU MOTOR
Toyo No. : 8549 - 01
NO. NG ITEM JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER TOTAL NG RATIO
1 MIRROR (Bintik) 0 0 0.00%
MIRROR
2
(Marking) 0 0 0.00%
3 LEVER 3 3 0.16%
4 STAY 4 4 0.21%
5 Mirror ( Garis) 1 1 0.05%
Mirror
6 0 0 0.00%
( Gompal)
Mirror
7
( Noda) 0 0 0.00%
8 Bracket 0 0 0.00%
9 Housing 3 3 0.16%
10 Noise 0 0 0.00%
Torque 20 20 1.06%
TOTAL NG 31 31 1.64%
TOTAL OK 1,856 1,856 98.36%
TOTAL
PRODUCTION
1,887 1,887

% NG 1.64%
% OK 98.36%

QUALITY COMPARISSON TABLE

100% 98%

90%

80%

70%

60%
RATIO

50% Row 23
40% Row 22
30%

20% Date : Desember 07

10% Approved Checked Prepared

2%
0%
Column Column Column Column Column Column Column I Column Column Column Column Column
C D E F G H J K L M N
MONTH
PT. PROGRESS TOYO ( INDONESIA )
Column Column Column Column Column Column Column I Column Column Column Column Column
C D E F G H J K L M N
MONTH

PT. PROGRESS TOYO ( INDONESIA )

 Action
Action Plan
Waktu Penyelesaian Waktu Perencanaan

Plan Verifikasi
Atasan
Nama Perusahaan : Nama : Jabatan :
1. Judul Tema 1. Dondy QC
PT. Progress 2. Sumarlin QC Incoming
Toyo 3. Ade Leader Assembly
Mengantisipasi kenaikan produksi dari PT.Yamaha Indonesia Motor Mfg tahun 2008 ( Indonesia ) 4. Ratna SubLeader Assembly

4. Penetapan Target

2. Latar Belakang 3. Pemahaman terhadap kondisi saat ini

* Target yang ingin dicapai :
Menurunkan ratio NG Torque
Ratio NG Inside rear view D99B Prisma bulan Oktober Dari hasil pengamatan, urutan item NG adalah :
mengalami kenaikan menjadi 5.36 % sehingga selisih dengan * Seberapa banyak : Menjadi 1.74 % ( 22Pcs)
standard yang ditetapkan 3.36 % ( Target NG : 2 % ) 2.00%
4.00% 3.74% 2.00%
3.50% 1.75% * Sampai kapan : Dec'07
3.00% 1.50%

NG Ratio
2.50% 1.25%
2.00% 1.00%
1.50% 1.31% 0.75%
1.00% 0.50% 5. Jadwal Kegiatan
0.50% 0.30% 0.25%
0.00% 0.00%
Lihat Jadwal Kegiatan
Torque Noise Mirror (Gar-
is)
NG Item

6. Analisa Sebab Akibat 7. Usulan Tindakan Pengatasan dan Pelaksanaan 8. Melihat hasil dan penguatan manajemen

Setelah dianalisa, faktor penyebab banyaknya NG Torque 1. Konfirmasi ke vendor untuk dikirimkan
adalah : part sesuai standard

1. Dimensi Stay & Bracket tidak standard 2. Memberikan pelatihan

2. Opertor belum Trainning
3. Electric Driver rusak 3. Perbaikan Electric screw driver & Dibuat 9. Standarisasi dan penguatan manajemen
( Lihat Diagram Analisa Sebab Akibat ) jadwal Pemeliharaan

( Lihat Diagram Sistematik dan Matrix )

10. Rencana yang akan datang

Torque Noise Mirror (Garis)
3.74% 1.31% 0.30%
2.00% 2.00% 2.00%
 JADWAL KEGIATAN
Rencana Aktual
NOV'07 DEC''07 JUMLAH
DISKRIPSI LANGKAH PELAKSANA
1 2 3 4 1 2 3 4 PERTEMUAN

Pemilihan Tema

Pemahaman kondisi saat ini

Analisa faktor Utama

Tindakan Pengatasan dan

Pelaksanaan

Melihat hasil dan Efektifitas

Standarisasi dan Hasil Efektifitas

Standarisasi dan Penguatan

Manajemen

Rencana yang akan datang

Waktu konsultasi dengan atasan

 DIAGRAM Analisa Sebab Akibat

MANUSIA METODE

belum
paham point Tidak SOP kurang
Point cek
pemeriksaan Teliti detail
belum ada

Inspector
Belum
Trainning

Operator
Kenapa banyak
Mirror Assy D99B
Prisma NG Torque
dibulan Oktober '07

Electric Air Jig Assy

Screw driver Rusak
rusak Dimensi Stay
tdk std
Komponen
Part tidak
Air Screw driver
bagus
Push Pull belum Dimensi
rusak di Kalibrasi bracket tdk std

MESIN MATERIAL
DIAGRAM SISTEMATIK & MATRIK Eff App Urg Score
MENGURANGI NG RATIO TORQUE
BULAN OKT ' 07 Memberikan
Pelthan Inspeksi 3
Inspector Memetapkan
bahan Pelthan 3
Inspeksi
Menjelaskan
Point cek 3

Mengurangi NG Ratio
Torque Model D99B
Prisma Bulan Okt'07 Pemeriksaan 9
Dimensi Bracket
Komp.Part
Pemeriksaan
tdk bagus 9
Dimensi Stay

Konfirmasi
Vendor 9

Perbaikan Electric
Screw Driver 8
Elect. Driver
rusak Jadwal
Pemeliharaan 8
Berkala

Legend :
: 1
: 2
: 3
 USULAN TINDAKAN PENGATASAN
DAN PELAKSANAAN

Rank Jenis Tindakan Pelaksana Kapan Biaya Sasaran

Pemeriksaan Dimensi
1
Bracket & Stay

2 Perbaikan Screw Driver

Memberikan Pelatihan
3
( Trainning )