.
LAMPIRAN
59
Lampiran 1. Struktur organisasi perusahaan
60
Lampiran 2. Sturktur organisasi divisi Purchasing
61
Lampiran 3. Kegiatan yang dilakukan
62
Lampiran 4. A3 report
63
64
Lampiran 5. Time Sheet Study Time study Sheet Kegiatan Operator Nama subjek Jenis kelamin Tinggi /berat Usia Hari/tanggal Jam Cuaca Kegiatan :
: : : : : : :
code cm tahun
: /
suhu
:
kg
kebisingan :
65
Lampiran 6. Grafik denyut jantung saat kalibrasi step test
66
Lampiran 7. Grafik persamaan WECst dan IRHR
67
Lampiran 8. Grafik HR kerja operator crankcase
68
Lampiran 8 (lanjutan). Grafik HR kerja operator crankcase
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
PT. TOYOTA MOTOR MANUFACTURING INDONESIA PURCHASING DIVISION PURCHASING NO.1 DEPARTEMENT
Name : Aqmarina Indra Education : S1 Institut Pertanian Bogor(Teknik Mesin dan Biosistem) Departemen : Purchasing no.1
Checked
Prepared
A. Hatmadji
Wahyu SP
Aqmarina Indra
Theme: Cost Reduction Activity Date :
I. PERSONAL DETAIL
Approved
23
/
June
2011
/
Sheet Number
Internship Period : 21 March - 20 Jun 2011 Division : Purchasing
I. BACKGROUND Vehicle sales and production in domestic market will reach 1 million unit/years in 2014. 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 >
SEAT 13 %
TBINA 0.00%
to be the best cost in Asia region
< Point of occurance >
material cost
SGT: - 1.11 % (-Rp 3,605 B)
Achieve 2011 cost reduction : 2.5 % Rp 105,203 B
IR3 : -0.52% (-Rp 791 B)
Interior and electrical section - 1.63 % (- Rp 33, 822 B)
RESIN 6%
Buyer still no have actual information about material and process
depreciation
FTR:- 1.05 %(-Rp ( p 914 B)) RUBBER 4%
IRC:- 0.54 %(- Rp 398 B) ITG:- 0.5 % (-Rp 271 B)
Service and component section + 0.2 % (+ Rp 580 B)
IKP
: - 0.49%
OTHERS 1%
NITTO :0.00 % AMT : 0.00 %
< Machine >
Machine not influence to get information
< Methode >
< Material >
data that affect CR not enough (raw data)
no actual methode to get information that influence CR
buyer experience is low
no collection data which content with CR
no training for new buyer
ii. Apakah mungkin dikurangi ketebalan (thickness ) part
Buyer have many work and don't have time to arrange
c. Pecahkan masalah yang ada berdasarkan aspek-aspek yang mungkin Seperti design , metode manufacturing , tenaga kerja, biaya mold , dan lain-lain Rencana perbaikan
< Man >
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
no manual book
2. Cara untuk mengembangkan ide a. b.
Benchmarking atau studi banding Diskusi
c.
Genchi Genbutsu
3. Proses cost a. Cek berapa mesin tonnage yang sebaiknya digunakan
< Root Cause >
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
< Countermeasures >
d. Cek apakah cycle time atau mesin tonnage yang digunakan dapat diganti e. Apakah mungkin coating suatu part tersebut dihilangkan
Step 7 Evaluation process and result
Before improvement
no information about material
no information about process make a part
no standarization to find CR
After countermeasures
Evaluation result
there is a information or guidance about material (specification material, consumption resin material, and source raw material) All data about material, process, cost, there is a information or guidance about process and how to get CR already (step to make part with arrange injection, how to determine machine tonnage, cycle time, and cost) there is a standarisasi
Activity
Dimana
Kapan
study material (resin material)
TMMIN
Apr
study process injection
Supplier
4-Apr
TMMIN study plating
Supplier
Genba (process, material)
Supplier
study how to determine machine tonage
Supplier
study calculation cost
TMMIN
study plating cost
Supplier
Bagaimana reading book meet supplier meet engineering
11-May
Masalah yang ditangani
item
Genba bertemu engineering
4Apr 20May 24Maret 31Maret
Evaluasi
Genba Genba meet supplier, discuss with supplier, departemen head and section head
meet supplier, discuss May- June with supplier, departemen head and section head meet supplier, discuss 9-Jun with supplier, departemen head and section head
Step 6 See Countermeasures Through
All actual information about process cost, material cost, and to find CR, kadai already checked, arrange in one manual book
man, metode
Root Cause
Countermeasures I
Apr II III IV
V
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
Schedule May I II III IV
V
I
June II III
Step 4 Root Cause Analysis
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)
d.
RFQ
DWA : 0.00%
1. Langkah yang disarankan a.
FOH
ICH: 0.99 % (Rp 745 )
Ch Chassis i and d engine i section ti - 0.11 % (- Rp 623 B)
Cost reduction achievement still : - 1.99 % Rp 83,853 B (non-CPP)
Quatation received
< Problem to Tackle >
DLD :1.29 % (Rp 1,196 B)
Body and exterior section + 1.03 % (+ Rp 12,515 B)
< Current Situation >
cost evaluation
cost
AOP : - 1.25% (-168 B)
< Problem >
Unachieve cost reeduction - 0.51 % Rp 21,350 B
GENBA
process
< Break Down>
< Ideal Situation >
Benchmarking Activity
Step 3 Target Setting
Contribution
Price approval
