Shopfloor Best Practices

PT PERFETTI VAN MELLE INDONESIA
Candradimuka Excellent Center

9 October 2009
Page 1
SHOPFLOOR BEST PRACTICES
Shop Floor Best Pratices
Activities:
1.5S Program
Objective:
2.Group Leader Enhanchement
3.Shop Floor Meeting
4.Q-Sign
5.Control Critical to Quality (CTQ)
A '5S' is a system which driven enhances productivity and

competitiveness and fosters a productivity culture through
workplace organization and a continual process of identifying,
reducing and eliminating MUDA (Japanese for Waste).
5 S as a fundamental to all continuous improvement activities.

Objective of 5S are:
•Identify, Reduce and Eliminate MUDA (waste)
•Organize & establish a World Class workplace
•Enhance Productivity & Competitiveness
•Improve work life
Page 3
5S Program
5S stands for:
1. Seiri / Sort
Clearly distinguish necessary items from unnecessary
items and eliminate the unnecessary.
2. Seiton/Shine
The regimented, scheduled, standardized cleaning of the
work area.
3. Seiso/Set in order
Keep only necessary items in the correct place for quick and
easy retrieval.
4. Seiketsu/Standardize
Tools used to maintain the first three S’s.
5. Sitshuke/Sustain
Sustaining is performing and improving the 5S’s on an ongoing
and regular basis.
Page 4
5S Program
Page 5
5S Program
2007 2008 2009
a. Impleme
nt Short
b. Impleme
nt Set in
order
c. Impleme
nt Shine
Page 6
5S Program
Sustain
Standardize
Pilar
Pilar Pilar
Set in
Short Shine
Order
Awwareness of All Employees
Commitment of Management
4 steps to implement 5S program:
1.Commitment of Management
2.Awwareness of all employies
3.Implement 5S Program
4.Evaluation 5S Proram by Competition 5S
Page 7
5S Program
Management conduct the Lean Manufacturing Program and 5S

Program was be developed and maintananced by it.
This is a example of contract sheet in LMP ;
5S Program
Page 8
5S Program
To keep continuing 5S campaign to all employies by 5S Training;
Opening Refreshment 5S by Pak Isack
Rule of The Competition by Anang YR Participants, serious but relaxed
Page 9
5S Program
Training-Audit sesion
Page 10
5S Program
Rule of the Competition :

1. The Auditor Team will give the score Every Audit.
2. The Auditor Team will choose the Winner and the Looser every
month base on the score
3. The Winner Area will receive the Gold Flag and the Looser Area
will receive the skull flag
4. The score will be accumulated and on the end of competition will

be decided who the WINNER is.
Page 11
5S Program 5S Recognition Board:
Area name
Period of audit
The Badge for score

under the standard
The Badge for score

in the standard
The Badge for score

above the standard
The Banner for

highest score
Page 12
5S Program
5S Recognition Board:
The Banner for

lowest score
Page 13
5S Program
Develope and upgrade the checklist
For 5S Audit
Page 14
5S Program
•Inauguration of 5S Auditor (Confirmation as 5-S auditor in CBN)
Dengan ini kami mengangkat Tim

Auditor 5-S yang berkomitment untuk
mensukseskan Program 5-S di
PT.Perfetti Van Melle Indonesia
Page 15
5S Program
•Inauguration of 5S Auditor (Confirmation as 5-S auditor in CKP)
Page 16
5S Program
•Coaching 5S Auditor by Plant Director
Indoor Outdoor
Outdoor
Page 17
5S Program
•Up grade 5-S audit standard (socialization new checklist at CKP )
Socialization to CKP-area owner by 5-S Coordinator , May 29, 2009

on Srikandi Room
Page 18
Devide Plant Cibinong and Cikampek to some area 5S
Page 19
5S Program
Foto audit oleh auditor
Page 20
5S Program
•Result Audit 5S Period September 2009 Cibinong
Production Supporting Production

Cross Functional Team, Make more and more, better and better
LMP III, 2009 Page 21 with less and less…
5S Program
•Result Audit 5S Period September 2009 Cikampek
Production Supporting Production
Page 22
5S Program
Monthly Recognition Event
Page 23
5S Program
Yearly Recognition Event
For 5S WINNER
Page 24
4 Activities:
a.Selection The Group Leader

b.Comprehensive Training
c.Review Group Leader Performance
d.Shop Floor Management Coaching
Page 25
a. Selection The Group Leader
Review Organization Structure
a.Selection The Group Leader
Interview and Selection
All candidates will be tested and interviewed about;

a.Process knowledge and know how
b.Knowledge of equipment, machine, skill, extr
c.Decipline
d.Moral improvement
e.Compliance culture
f.Leadership
g.Self Confidence
h.Human relationship
i.Problem solving
Page 27
b. Comprehensive Training
Develop Group Leader Training Module

Focus Program :
a. Process and Production Knowledge
b. People Development
c. Learning Organization
d. Cost Overview
e. Quality Overview
Focus Program divided into 38 training modules

38 Training Modules
Make more and
Phase 1 : Floor Supervision more, better and

better…with less
and less !
Training Execution :
• Executed May – Aug 2007
• Coverage all training modules
• Training delivered by competent internal resources
• At the end of every training completed by a test
• All Group Leaders should pass all tests
• Finished by Group Leader graduation
Make more and
Phase 1 : Floor Supervision more, better and

better…with less
and less !
b. Comprehensive Training Training Execution

Training Opening Hygine Training
5S Training
Spirit of ice breaking

Phase 1 : Floor Supervision
Thinking Out of the Box
Make more and
Phase 1 : Floor Supervision
SHOPFLOOR BEST PRACTICES more, better and
better…with less
and less !
Q & A Session
Training Execution – Closing & Graduation

Fantastic Games

Self Reflection

Graduation

Strategies : 3. Training Execution – Closing & Graduation
Graduation
c. Review Group Leader Performance
Review Group Leader #2, August 20, 2009 on Krakatau Room
Page 38
d. Shop Floor Management Coaching (SFMC)
SFCM is a coaching for Group Leader of the area by Plant Manger
and Production Manager and followed up by a touring on the floor to
review several issues: safety, schedule, quality, leaderships and
others
The coaching methods :
• In the room : for approximately 5 minutes
• On shop floor : for approximately 25 minutes
This coaching monitored by using “Progress Report Form” and in the

year end period will be reviewed and used to support annual
appraisal for Group Leaders
Page 39
The Schedule of coahing

Page 40
The Progress report form

Page 41
Progress Report Form for
Coaching
minimum achievement score must be 7
Page 42
0
2
4
6
8
10
12
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pz
Sa en
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Ku raw
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aw
an
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Ka adi
te
Page 43
ra
ng
Fa
rid
A
Yu dhi
10 10 10 10 10
Sy won
ai
ch o
8
ud
in
9
De
ni
E
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Fi ka
rd
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au
s
Jo
ko
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Achievement Score for Group Leader Coaching
Um
a
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Na r
sa
Sl ri
am
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et
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Ru
di
Ya
10
z id
7
Pu
dj
i
8
Cibinong Cikampek
4 Group Leaders 2 Group Leaders
REWARDS :
Best Group Leader based on coaching achievement score per
line will be recommended as team building relevant invited
participants next year
Page 44
SFM is a meeting within Group Leaders and Operators

Executed in a standing meeting format on the floor at the
beginning of the shift
The main topic discussed : safety, schedule, quality and other
related issues
Objectives ;
i. Streamlining communication and direction
ii. As communication pipe for all company programs
iii. Quick responds and up date from operators
iv. Improve level of urgency
v. Easier to deliver production brief/issues
Page 45
SFM
SFM
Lay Out shop floor meeting area

Page 47
Guest speaker from engineering Guest speaker from NPD Guest speaker from Production
Guest speaker from engineering Guest speaker from SHE Guest speaker from QC
Page 48
Cibinong Cikampek
G r a f ik K e h a d ir a n S h o p F lo o r M e e t in g G r a f ik K e h a d ir a n S h o p F lo o r M e e t in g
1 0 0 .0 % 1 0 0 .0 %
9 0 .0 % 9 0 .0 %
8 0 .0 % 8 0 .0 %
7 0 .0 % 7 0 .0 %
6 0 .0 % 8 9 .5 % 6 0 .0 %
9 6 .0 % 9 3 .0 % 9 6 .5 % 9 4 .5 % 9 7 .4 % 9 7 .4 % 9 4 .5 %
5 0 .0 % H a d ir 5 0 .0 % H a d ir
4 0 .0 % 4 0 .0 %
Ab se n Ab se n
3 0 .0 % 3 0 .0 %
2 0 .0 % 2 0 .0 %
1 0 .0 % 1 0 .5 % 1 0 .0 %
4 .0 % 7 .0 % 3 .5 % 5 .5 % 2 .6 % 2 .6 % 5 .5 %
0 .0 % 0 .0 %
D r a g e eP a c k i n gC h e w y A l p e n A B C D
G ro u p G ro u p
Page 49
Q-Sign is a quality sign which be installed at the critical area

which all employees should be awware to the quality
of product.
It consist the sign and one point lesson (direction) for operator
to control the isue of product defect.
Page 50
•Implement widely Q-sign with ‘one point lesson’ structure
Q-sign picture
Page 51
Compliance of Cleaning Filter, Magnetic Trap and Metal Detector

Filter Magnetic Trap Metal Detector
Page 52
Compliance of Cleaning Filter
Cibinong Cikampek
100% 100% 91%

100% 100%
100% 89%
Data compliance
80% 73%
cleaning filter 100%
80%
Dragee
80% 100.0% 75%
80%
Alpenliebe
60% 100.4%
Chewy
40%
91.2% 60%
Average 97.2% 40%

20%
20%
0%
N o ve m b e r Desem ber
0%
D ra g e e A lp e n lie b e Chew y N o ve m b e r D esem ber
C o a te d F o rm in g
Page 53
Compliance of Cleaning Magnetic Trap
Cibinong Cikampek
100%100% 1 0 0 %1 0 0 % 1 0 0 %1 0 0 %
100% 100% 100% 100% 100% 100%
Data com pliance celaning m agnetic trap
100%
100%
80%
Dragee 100.0% 80%
60%
Alpenliebe 100% 60%
Average
40%
100.0% 40%
20%
20%
0%
O ld S D N e w S D A lp e n lie b e 0%
Babol C h e w y c o a te d G o lia fo rm in g
No ve m be r D e se m b e r
N o ve m b e r Desem ber
Page 54
Page 55
Compliance of Cleaning Metal Detector
Cibinong Cikampek
100% 9 0% 92 %
Data com pliance
90% 9 0%
m9 etal
0 % 90 %
detector 100%
100% 100% 100% 100% 100% 100%
80%
Dragee 91.9% 80%
60%
Alpenliebe 90.0% 60%
40%
Chewy 90.0% 40%
20%
Average 90.6% 20%
0%
Dr a ge e Alpe nlie be C he w y
0%
Babol C h e w y c o a te d G o lia fo rm in g
N o ve m b e r D e se m b e r
N o ve m b e r D es em ber
Page 56
Page 57

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PT PERFETTI VAN MELLE INDONESIA

Candradimuka Excellent Center

Shop Floor Best Pratices

A '5S' is a system which driven enhances productivity and

5 S as a fundamental to all continuous improvement activities.

2007 2008 2009

Management conduct the Lean Manufacturing Program and 5S

Rule of The Competition by Anang YR Participants, serious but relaxed

Rule of the Competition :

4. The score will be accumulated and on the end of competition will

The Badge for score

The Badge for score

The Badge for score

The Banner for

The Banner for

Dengan ini kami mengangkat Tim

Socialization to CKP-area owner by 5-S Coordinator , May 29, 2009

Foto audit oleh auditor

Production Supporting Production

Production Supporting Production

a.Selection The Group Leader

Interview and Selection

All candidates will be tested and interviewed about;

Develop Group Leader Training Module

Focus Program divided into 38 training modules

Phase 1 : Floor Supervision more, better and

Phase 1 : Floor Supervision more, better and

b. Comprehensive Training Training Execution

Spirit of ice breaking

Training Execution – Closing & Graduation

Training Execution – Closing & Graduation

Training Execution – Closing & Graduation

Training Execution – Closing & Graduation

Strategies : 3. Training Execution – Closing & Graduation

Review Group Leader #2, August 20, 2009 on Krakatau Room

This coaching monitored by using “Progress Report Form” and in the

The Schedule of coahing

The Progress report form

minimum achievement score must be 7

SFM is a meeting within Group Leaders and Operators

Lay Out shop floor meeting area

Q-Sign is a quality sign which be installed at the critical area

•Implement widely Q-sign with ‘one point lesson’ structure

Compliance of Cleaning Filter, Magnetic Trap and Metal Detector

Compliance of Cleaning Filter

100% 100% 91%

Average 97.2% 40%

Compliance of Cleaning Magnetic Trap

Compliance of Cleaning Metal Detector

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