Improve Operation Scrap Ratio at Sachet Line

QC Circle Activity
PT Kao Indonesia - Factory
Improve operation scrap ratio at

FHC Packing
By : Eka Nuryanta
Date : 21 December 2009
Introduction Team Name and QCC Members
Team: SEMUT HITAM

Motto: BERSAMA KITA BISA !!!
Work Place: FHC Packing
Copyright © 2007 KAO CORPORATION. All rights reserved. 1

Introduction Team Name and QCC Members
Sponsor Kikugawa
Promoter Hendra A./Andy B./Irwan H.
Adviser Oka/Okamoto Secretariat M. Istari/Gulut H.

Average age: 37
Average service year: 12 FHC AsMgr FHC Sect Mgr
Number of meetings (@60min): 20
Presence: 90 %
QCC Level Skill of member
before QCC Prod Admin
Nuryanta
8
rata-rata Momo
6
4
Andi nanang
2
Bayhaqi
0
asmuni
Pictures Ardi K Yunsirwan
syarkowi sutrisno Facilitator Facilitator
adha
Team work 8 step 7 tools Idea

Nuryanta
Engineering Maintenance QC G Leader Line Leader QCC Leader Line Leader Line Leader Line Leader Line Leader
Bayhaqi Andi Momo K Syarkowi Adha N Sutrisno Asmuni Nanang S

QCC Support QCC Support QCC Secretary QCC Member QCC Member QCC Member QCC Member QCC Member

Problem List in Workplace
Data taken on Marc 08
No Problem at FHC Packing (Filling) Fact
1 Facility (Machine) performance Some line not achieved target
2 Quality Issue 2006: 9 Customer Complaint 2007: 5 Complaint
3 Environtment Quality Noise at FHC Packing not comply with legal requirement & Fine dust problem
4 FHC Packing Operation scrap amount 2006 : 3,23 Bill Rp 2007 : 2,23 Bill Rp ~ Mar 08: 1,67 Bill Rp
1st priority?
BRAINSTORMING PARETO BRAIN STORMING

Mo Ad Kum
100% 100,0%60
No Nur Nang Sut Asm Total % 90%
mo ha % 50
80% 78,8%
% Kumulatif
Total point
1 1 2 4 4 3 2 16 26,3 55,8 2 70% 40
60% 55,8%
2 3 4 3 1 1 1 13 21,2 100 4 50% 30
3 2 3 1 2 2 3 14 23 78,8 3 40%
30% 29,5% 20
4 4 1 2 3 4 4 18 29,5 29,5
1 20% 10
Note: Total 61 100 10% 18,0 16,0 14,0 13,0
1 = Normal priority 0% 0
2 = Important to solve 3 = More Important 4 = Very Important 4 1 3 2
Group of Problems
Background>Target>Plan>Cause>Countermeasure>Result>Standardization>Conclusion
PLAN: Step 1: Theme & Reason Theme Selection
QCC Theme:
“Improve Operation Scrap Ratio

at FHC packing”
Reason for chosing this theme:
1. Agreements of QCC member
2. Based on the highest Pareto problem
3. As basic production activity control
4. Approved by the management
5. This activity, if successful could raise operating income of FHC
PLAN: Step 1: Theme & Reason Theme Selection
Marketing
Expense
Operating
Income
Fixed Marginal
Expenses income
Net Variable Scrap is part of
Sales Direct material
COGS in variable
COGS
calculation
P&A Overhead SCRAP
RATIO Lower
scrap will
V Selling Direct gain up
Expenses Direct Material profit
Labor Theoretical
Qty
PLAN: Step 2: Understanding the Problem and Set Priorities
What really scrap is ?
Scrap ratio:
A ratio that expresses (usually as a decimal value) the quantity of a particular component that is expected to be
scrapped upon completion of production or while that component is being built into a given assembly
APICS Dictionary, Tenth Edition
Practical: KAO:
Scrap = Actual Value - Nominal Value
Net weight of product
weight listed
In the package
Operation Scrap Amount of FHC Packing
4,50 1,50% 1,6%
1,39%
4,00 1,4%
1,20%
3,50 1,2%
3,00
1,0%
2,50
0,8%
2,00
0,6%
1,50
1,00 0,4%
0,50 0,2%
0,00 0,0%
2006 2007 Jan ~ Mar 08
Amount Bill Rp 3,23 4,03 1,67
Ratio (%) 1,20% 1,39% 1,50%
Budget Qty of direct Material = Theoretical Qty + Operation scrap ratio (%)
PARETO OPERATION SCRAP AMOUNT
Breakdown by sources... FHC PACKING Jan ~ Mar 08
1.800.000.000 100% 102%
100% 100%
Pareto amount of scrap powder by Line 1.600.000.000 99% 100%
1.400.000.000
Thousands Rp
900,000,000 120.0%
98%
Amount of Scrap (Jan ~ Mar 08)
1.200.000.000
800,000,000
100.0%
100.0% 1.000.000.000 96%
700,000,000 96.6%
92.2% 800.000.000
84.5% 93% 94%
600,000,000 80.0% 600.000.000
92%
500,000,000 400.000.000
57.9% 60.0% 90%
400,000,000 200.000.000
300,000,000 40.0% 0 88%
Powder Sachet Karton OPP tape Gusset
200,000,000
20.0% Break down by Materials
100,000,000
0 0.0%
Powder is most caused (93 %) of scrap
Sachet Ln
Gusset Ln
Manual
Sachet
Gusset
HH -
HH -
HH -
amount happened in sachet line

HH -
ND2
HH -
ND2
Line Filling
84,5 % of 1,67 bill Rp amount of scrap

happened in Sachet Line
1st Priority
(jan-Mar 08) To solve powder scrap in
line sachet
PLAN: Step 3: Target Setting and Reason
“Reduce Operation Scrap ratio of Powder at Sachet line FHC
packing as 25% down By end of QCC Activity”
Actual Scrap FHC Line sachet
2008
2.6
2.4
25 % down
2.2
2 Average
= 2.5%
1.8
1.6
1.4
Target 1.9 %
1.2
2.5 % 1.9 %
1
Jul
Aug
Jun
Sep
Jan
Feb
Apr
May
Nov
Oct
Mar
Reason :
1. Closed to the Theoretical Accepted Scrap (Nominal Value + 0.5 Sigma)
2. Agreements of QCC member (consider to level skill of QCC member)
PLAN: Step 3: Target Setting and Reason
“Reduce Operation Scrap ratio of Powder at Sachet line FHC
packing as 25% down By end of QCC Activity”
Opportunity saving:
Assumed Yearly Scrap amount = 4 billion rupiah
If we can reduce 25 %, it means 1 billion rupiah
FUTURE
TARGET:
Zero Scrap
PLAN: Step 4: Planning of activity plans
2008 2009
P D
STEP ACTIVITY A
P
M
A
J
U
J
U
A
U
S
E
O
C
N
O
D
E
J
A
F
E
M
A
A
P
M
A
J
U
J
U
A
U
A C R Y N L G P T V C N B R R Y N L G
1 Theme selection
Understanding of present
2 situation
PLAN
3 Setting of goals
4 Planning of activity plans
5 Factor analysis
DO Coutermeasure study and
6 implementation
CHECK 7 Effect confirmation
Standardization,
ACTION 8 Reflection and future plans
Note:
PLAN ACTUAL
DO: Step 5: Factor Analysis Caused Scrap amount High
Current Method for reporting powder consumptions:
Powder
Consumptions of “X” powder calculated based on the quantity
Stock Bin recipes(BOM) plus scrap predetermined, rather than actual consumption
Powder “X” Kg
Packaging Filling
material M/C FG
... Reporting as recipe,

rather than actual
consumption is the
DOMINANT FACTOR
caused total scrap
amount are HIGH !
So we must found method / tools for grasping actual consumptions
Background>Target>Plan>Cause>Countermeasure>Result>Standardization>Conclusione
DO: Step 5: Factor Analysis (MACHINE)
Flow diagram of filling Machine sachet
Powder
(Semi FG) Measuring Sachet Finished
Cutting Cartoning
cup forming Goods
Sachet
film Inspection
-Volume of Measuring cup change due to

-Shutter plate bend
-Bushing loose adjustable
-Powder caking, etc
DO: Step 5: Factor Analysis (METHOD)
Daily weight control methods
Raw data, should be processed in more eye catching in order to facilitate
operator make an improvements
 it could be caused operator do late for machine adjustment
Std vs Actual Scrap Line 1

2.50%
Conducted at the end
2.1%
2.00% 2.0% of the shift, too late to
1.9% make an improvements
Actual scrap (%)

1.8%
1.6%
1.50%
1.4%
1.2%
1.00% 1.0% 1.1% 1.0% 1.0%
0.9%
0.8%
0.8% 0.8%
0.6%
0.50%
Not
0.2%
0.1% 0.1%
0.0%
effective
0.00%
!
2
10
12
16
18
20
24
26
Date
Actual Scrap Standard Scrap
DO: Step 5: Factor Analysis (CAUSED & EFFECT)
Man Machine
Different weight
in each cup
Vol adjusment Less of m/c
too late knowledge Shutter plate
bend
Less of Change size /
manufacturing design Scrap
cost knowledge Old machine
Ratio Powder
2.5 %
Grasping Actual
Bulk Density to Consumptions as
Vary BOM
No method Current daily

grasping actual weight control
consumption not yet enough
Material Method
Grasping / reporting consumptions as BOM (recipe)

are the dominant factor caused amount scrap powder 2,5 % equal to
1.45 Billion Rp.in Jan ~ mar 08 periode.
DO: Step 6:Countermeasure Study & Implementation I
Cause & Countermeasure plan
Effect / Due
FACTOR Cause Why Location Counter-measure PIC
Consequence Date
Grasping /
Reporting
Scrap ratio will be There is no method Study & develop
actual
reported as / WI due to how to FHC new method for
consumptions Nuryanta JUL
METHOD standard even grasping actual Packing grasping actual 08
based on the actual scrap is consumptions of all line & Momo
consumption of
BOM standard, lower than powder powder
not the actual
genba.
Measuring step by
volumetric cup was not FHC
Heavier / lighter -Create check
Problem in accurate due to: Packing Bayhaqi AUG
MACHINE products (higher / -Bushing loose
sheet for stopper
shutter plate all line & Andy 08
lower scrap) -Shutter bend as
position
sachet
powder caking
FHC Tooled with new

Volumetric Heavier / lighter Operator not equipped
method:
with effective tools to Packing Line AUG
MAN adjustment too products (higher / control weight of all line -Actual consumption leader 08
late lower scrap) product sachet -Daily weight control
FHC
Heavier / lighter Weight =
Bulk density to Packing
MATERIAL products (higher / Volume of CUP (cm3) External factor -
vary x BD (gr/cm3)
all line
lower scrap)
sachet
Countermeasure Action: Develop new Method for grasping actual powder consumption
No Countermeasure Activity PIC DATE Countermeasure Result
1.A Study & develop new method: Nuryanta JUL

1.1. STATISTICAL Approach & Momo 08
Evaluation Scoring
Evaluator:
1 2 3 4 5
All QCC
Member
More better
Aspect Score
Principe: Check actual weight of product by sampling each 30 Accuracy 2
minute, Powder consumed counting base on average weight of
product X total product of the day Easier 5
Cost 5
Safety 5
Speed 1
Total 18
Countermeasure Action: Make new Method for grasping actual powder consumption
1.A Study & make new method: Nuryanta JUL

1.2. Manual job & Momo 08
Evaluation Scoring
Principe: Quantity of powder are counted and measure as manual
total powder charged into hopper Machine filling, Total buggies + Evaluator:
powder remain in hopper = powder consumed.
1 2 3 4 5
All QCC
Member
Supply powder scheme More better
Aspect Score
Accuracy 3
Easier 2
Measure powder Cost 5

remains in hopper
Safety 2
Speed 1
Discharged powder Total 13

from stock bin and Charged into
weighed at load cell machine hopper
1.A Study & develop new method: Nuryanta AUG

1.3. Automatic & Momo 08
Evaluation Scoring
Principe:
Product weight recorded at weight checker unit. Average of Evaluator:
1 2 3 4 5
product weight of the day x total product – weight of packing All QCC
material = Powder consumed. Member
More better
Aspect Score
Weight checker unit
Accuracy 4
Easier 5
Cost 1
Safety 5
Speed 5
Total 20
Spread of weight product can be
monitored real time from PC
1.A Study & develop new method: Nuryanta AUG

1.4. Semi-Automatic & Momo 08
Evaluation Scoring
Principe:
Weigh checker combined with manual job. Evaluator:
1 2 3 4 5
Flow of method:
All QCC
Member
More better
start
Aspect Score
Net Qty at PO
Fill in form
Reset filled with value
Weight-checker
“hitung powder”
from new method
Accuracy 4
unit
Easier 5
Get the value end
Set DISPLAY of actual
Powder Highest Cost 5
to X run chart
consumptions score !
Let’s apply Safety 5
Take X value to the daily
Fill in column Speed 4
Cons SFG operatios
Take sample form “Laporan
of weight Operasi Mesin” Total 23
of sachet /
gusset & carton
Detail proposed New Method for grasping actual consumptions
Semi-Automatic Form
Manual activity combined with data taken

From weight-checker unit
Countermeasure Action for Shutter plate problems
2 Stopper position standardization: to be (3 mm) Bayhaqi, Aug

To avoid : empty sachet /
Andy & 08
Weight less than standar caused
Create check sheet Momo
Shutter not open properly
standard for stopper &
shutter plate checking
2 Add item bushing & stopper check on maintenance check list Andy & Aug To make sure shutter plate
momo 08 working properly
Activity
done by
Line leader
& line
operator
CHECK: Step 7: Result of Countermeasure Actions
Result of Countermeasure Action for Method & Shutter plate problems
Standard vs Actual Scrap ratio (% )

3.00
2.50 2.56
2.00 2.62
1.84
1.50
Before activity
1.00
0.50
Countermeasure
ACT Scrap
0.00 Ratio (%)
Average
3-Nov-08
4-Nov-08
5-Nov-08
6-Nov-08
7-Nov-08
10-Nov-08
11-Nov-08
12-Nov-08
13-Nov-08
14-Nov-08
15-Nov-08
17-Nov-08
18-Nov-08
19-Nov-08
STD Scrap
Ratio (%)
Starting New method
Result of Countermeasure Action for Method & Shutter plate problems
Scrap ratio After Implement New grasping powder Before:

consumptions Scrap ratio: 2,56 %
(Periode Nov 08~ Mar 09)
3.00%
After:
2.50%
Scrap ratio: 1,4 %
40 %
2.00%
down
1.50%
1.00%
2.50% Target:
0.50%
1.40% 25 % Scrap down
0.00% Actual:
Before QCC QCC Result (METHOD, 40 % Scrap down
MACHINE)
Countermeasure Actions are EFFECTIVE!
Result of Countermeasure Action I and Next Target:
Scrap ratio FHC Packing

3
2,5
56 % 25 %
2 down 40 % 60 %
down down
1,5 (MEAN + down
0,5 sigma)
2,5
1 1,9
1,4
0,5 1,1 1
0
Before Standard Target 1 Achieved Target 2
QCC (%) QCC 1
Lanjutkan
DAB !
Sssst....
Activity kita
belum selesai,
masih ada
ronde kedua
PLAN: Step 3: Target Setting
.......Next Target:
2nd QCC:
“Improve current actual scrap ratio (1,4 %)
as theoretical scrap”
Theoretical scrap*:
Mean =
Nominal Value + 0,5 sigma
* Established by QM Center KAO Jepang
2nd QCC:
Scrap ratio
<1 %
PLAN: Step 4: Planning of activity plans
Continuing activity from 1st QCC
DO: Step 5: Factor Analysis Caused Scrap amount High
Material & Man Ideal condition
(Relation betwen cup volume vs Density)
Weight = Volume Cup x Density of powder
Our Variable External factor 64 0,9
(out of control)
Density (gr/cm3)
control 62
Cup volume
0,85
60
(cm3)
58 0,8
56
0,75
Cup
adjustable
54
52 0,7
50
50
50
50
50
50
50
50
50
50
50
Telescoping cup
Weight Set (50 g)
Manual adjustment Volumetric cup Pow der Density
-Volume of cup change due to

-Shutter plate bend Gemba condition
-Bushing loose (Relation betwen cup volume vs Density)
-Powder caking 68.0 0.9
-etc
Cup volume
63.0 0.85
(gr/cm3)
Density
adjust
(cm3)
58.0 adjust 0.8
-Powder density are vary adjust
adjust
(spec 0.79 ~ 0.89 gr/cm3) 53.0 adjust 0.75
48.0 0.7
52.5
52.5
51.2
49.1
50.3
49.7
48.8
50.6
48.8
49.8
49.8
51.0
51.0
50.4
52.0
51.6
50.5
49.9
50.2
51.9
50.4
- Operator late for adjust telescoping cup.
- No direction (current data are in KAO’s spec) Weight result
- No data & tools to control the process
Volumetric cup Weight Result Powder Density
DO: Step 6:Countermeasure Study & Implementation II
Cause & Countermeasure plan
Effect / Due
FACTOR Cause Why Location Counter-measure PIC
Consequence Date
Sample of Inacurat Sample weight of FHC Improve new

computing powder carton not closed to Packing method, with do Line FEB
METHOD packaging too consumptions by actual due to few of all line Sampling carton for leader 09
less semi-auto method sample taken. sachet more pcs
FHC
Inadequate tools to
Packing Create control Line MAY
monitor spreads of
all line chart leader 09
Operator do late Heavier / lighter weight
sachet
MAN volumetric cup products (higher /
adjustment lower scrap) FHC
-Create WI for
Packing Line MAY
Inadequate WI volumetric cup
all line leader 09
adjustment
sachet
FHC
Heavier / lighter Weight =
Bulk density to Packing
MATERIAL products (higher / Volume of CUP (cm3) External factor -
vary x BD (gr/cm3)
all line
lower scrap)
sachet
Countermeasure Action
DUE
No Countermeasure Activity PIC Countermeasure Result
DATE
FEB Actual weight decrease, closed
1 100 pcs each item are weighed and taken average of weight Line leader
09 to nominal value
Study & develop new method for daily weight control
Time to time operational to

Nuryanta MAY control average weight, Action
2
& momo 09 will be done quickly if weight
out-spect found
Operator used control chart to monitor average of weight, so

volumetric cup adjustment can be done quickly Operator used control chart
to monitor average of
weight, so volumetric cup
Leader MAY adjustment can be done
3 quickly
Line 09
30
Detailed Countermeasure Action
New control chart for weight control
Before QC activity
??@#$%^&
Easy to eye catch, then quick action taken

31
Countermeasure Action
No Countermeasure Activity PIC DUE DATE Countermeasure Result
Momo &
4 Create WI & standardize volumetric cup adjustmen MAY 09 Clearly task
Syarkowi
New Working Instruction
Describe clearly with picture
Clearly task guide operator to do

daily control of packing operation
Understood !
1 = Trouble / Problem
2 = Cause
3 = Troubleshooting
32
√
CHECK: Step 7:Confirmations of Effectiveness

WHAT WHERE HOW WHO WHEN RESULT
Effect / Counter- Due

FACTOR Cause Why Location PIC STATUS
Consequence measure Date
Grasping / Reporting Study & develop
Scrap ratio will be
actual consumptions There is no method / WI due to new method for Nuryanta Already
reported as standard FHC Packing
METHOD based on the BOM how to grasping actual grasping actual JUL 08 done in
even actual scrap is all line & Momo
standard, not the consumptions of powder consumption of Nov 08
lower than
actual genba. powder
Measuring step by volumetric cup
was not accurate due to: FHC Packing -Create check
Problem in shutter Bayhaqi &
MACHINE all line sheet for stopper AUG 08 Done
plate -Bushing loose Andy
sachet position
-Shutter bend as powder caking
Heavier / lighter
products (higher / Operator not equipped with FHC Packing
Volumetric Tooled with new Line
MAN lower scrap) effective tools to control weight of all line AUG 08 Done
adjustment too late method leader
product sachet
Weight = FHC Packing
MATERIAL Bulk density to vary Volume of CUP (cm3) x BD all line External factor -
(gr/cm3) sachet
Inacurat Computing Improve new

Sample weight of carton not
Sample of packaging powder consumpti- FHC Packing all method, with do Line
METHOD closed to actual due to few of FEB 09 Done
too less ons by semi-auto line sachet Sampling carton leader
sample taken.
method for more pcs
Inadequate tools to monitor FHC Packing all Create control Line
MAY 09 Done
Operator do late Heavier / lighter spreads of weight line sachet chart leader
MAN volumetric cup products (higher / -Create WI for
adjustment lower scrap) FHC Packing all Line
Inadequate WI volumetric cup MAY 09 Done
line sachet leader
adjustment
33
√

….. Result of activity
STANDARDIZED
Scrap ratio of FHC Sachet Line SCRAP RATIO in BOM
3,0 (Master Recipe)
% Scrap of powder (SFG)
2,5
2,0
1,5 New Method of reporting
actual consumptions
1,0
improv e new method by 0,9
0,5 take more sample of
carton
0,0
Okt-08
Daily operation by control chart &New
Mei-08
Jun-08
Jul-08
Jan-09
Mei-09
Jun-09
Jul-09
Mar-08
Nop-08
Mar-09
Des-08
Feb-09
Sep-08
Apr-08
Apr-09
Agust-08
Agust-09
WI
Periode
Standard Scrap (Budget)
Actual Scrap
34
√

Scrap ratio of FHC Sachet Line

3.0
% Scrap of powder
2.5
2.0
(SFG)
1.5 Before QCC Activity

1.0
0.9
activity I
0.5
0.0 activity II
Mar-08
May-08
Mar-09
Jul-08
May-09
Oct-08
Jul-09
Nov-08
Dec-08
Jun-08
Jan-09
Feb-09
Jun-09
Sep-08
Aug-08
Aug-09
Apr-08
Apr-09
Periode Standard Scrap Actual Scrap
35
√

Scrap ratio After QCC Activity
(Periode Nov 08~ Mar 09~ Aug 09)
3,00%
2,50% 40 %
down 35 %
2,00% 64 %
down
1,50% down
1,00%
2,5%
1,4%
0,50% 0.9%
Total Activ ity
0,00%
result
Standard Actual (1st round Actual (2nd round
of QCC) of QCC)
Target: Result:
Powder scrap ratio Powder scrap ratio
<1% 0.9 %
Actual scrap ratio after completed QCC activity are
comply to KAO QM-Center
36
Merit Activity I
Scrap ratio After Implement New grasping Sachet Line (Nov 08~ Mar 09)
powder consumptions
(Periode Nov 08~ Mar 09)
3.00% STD Consumption Amount
2.50%
Equal to (STD SCRAP 2,6) Rp56,327,545,388
2.00% 40 % down
1.50%
2.50%
1.00% ACT Consumption Amount
1.40% Rp55,682,003,873
0.50% (Actual Scrap 1,4)
0.00%
Standard Actual
Saving Rp645,541,515
Total FHC (Nov 08~ Mar 09)
STD Consumption Amount
(STD SCRAP 1.7) Rp111,192,329,807
ACT Consumption Amount
Rp110,453,974,074
(Actual Scrap 1,0)
Saving Rp738,355,733
37
Merit Activity II
Total FHC (Mar 09~ Aug 09) Sachet Line (Mar 09~ Aug 09)
STD Consumption STD Consumption

Amount Rp178,670,640,026 Amount Rp94,435,330,544
(STD SCRAP 1,3) (STD SCRAP 2.5)
ACT Consumption STD Consumption

Amount Rp177,749,272,046 Amount Rp178,670,640,026
(Actual Scrap 0.8) (STD SCRAP 1.3)
ACT Consumption
Saving (1.3 to 0.8) Rp921,367,980 Amount Rp177,749,272,046
(Actual Scrap 0.8)
STD 2.5 % to 1.3 % Rp729,654,465
Saving Rp1,549,231,742
Total Saving FHC Rp1,651,022,445
38
Marketing
Expense
Operating
Income
Fixed Marginal
Expenses income
Net Variable
Sales COGS
P&A Overhead SCRAP

RATIO
V Selling Direct
Expenses Direct Material
Labor
39
ACTION: Step 8:Standardization
Process source of vary cause
Countermeasure Standardization
high scrap ratio
Approved standard
Proposed new Method (semi-auto) as
Grasping / reporting actual consumption method for powder
technique to obtains actual
done by standard BOM grasping actual
consumptions of powder
consumptions
Adjust telescoping cup too late, No tools & Develop : new control chart Register Form As ISO
guidance for control the process new WI Form
Volumetric Cup problems Register Form As ISO

- Create check sheet
(Volume of cup change; Less/over weight, Form
- Create WI
different volume each cup)
Control Chart as
Daily operation control using control
Less Control in daily operational standards tools for daily
chart
operations control
Operator (late do volumetric cup Using control chart (X, R) to control Established as standard
adjustment) average weight of product form
40
ACTION: Step 8:Conclusion, Reflection & Future Plan
QCC Activity resulted :
-Improved reporting material consumptions (powder), as standard recipe to actual consumptions
-Better daily operation management
-Improving production / manufacturing cost
-Skill up of member knowledge = Quality, Cost, Delivery, Safety & Moral
-Better understanding of QC 7 Tools, 8 Step Improvements and Ideas brainstorming
QCC Level Skill of member QCC Level Skill of member

before QCC before QCC
Nuryanta Nuryanta
8 8
rata-rata Momo rata-rata Momo
6
7,5
4
Andi nanang Andi 7 nanang
2
0 6,5
Bayhaqi asmuni Bayhaqi asmuni

Level up
syarkowi sutrisno
syarkowi sutrisno
adha
adha

Next Plan:
Wheels PDCA cycle, by continuing QCC Activity with next theme:

Improving scrap ratio of….
41
Bersama kita Bisa !
42
Q&A
Attachment
Scrap 2006 Scrap 2007 Scrap 2008 (jan~mar) Simulasi scrap sachet line
Pareto by line Pareto by material Scrap amount chart FHC
Itung-itungan

Target Setting and Reason
1. The Standard says…
Specification of the Mean
Average Filling Amount for manufacturing lot

Shall not be less than the nominal amount
Mean = Nominal value + 0.5 Sigma
Target Setting and Reason
2. Our Level (Current)
ACTUAL SCRAP RATIO (%) Actual Mean
Mar ~ Apr 08 Nominal Actual Weight Current Sigma
Weight (Std deviation) Standard: (Nominal + 0.5
2.60 (2.5 % scrap)
Sigma)
28 g 28.7 g 0.6 + 1.2 Sigma

2.55
60 g 61.5 g 0.6 + 0.8 Sigma
2.50 2.56 2.56
2.53 2.5
30 g 30.8 g 0.7 + 1.2 Sigma
2.50
2.45 65 g 66.6 g 1.35 + 1.2 Sigma
ND2 POWDER ATTACK ATTACK COLOR ATTACK AVERAGE
POWDER (D-23) POWDER (ACID- SOFTENER (ASID-
SFG 8) SFG 5) SFG Average 1.1 Sigma
3. …. Standard (0.5 Sigma)

Scrap ratio FHC Packing
Standard Mean
Nominal Current Sigma Standard 3
Weight (Std deviation) (Nominal + 0.5 Scrap (%) 25 %
2.5
Sigma) 25 %
56
56 %
% dow n
2
28 g 0.6 28.3 g 1.1 % down
1.5
60 g 0.6 60.3 0.5 % 2.5
1 1.9
30 g 0.7 30.6 g 2.0 % 0.5 1.1
65 g 1.35 65.6 g 0.9 % 0

Current (%) Standard Target
Average (0.5 sigma) 1.1 % 56 %

Improve Operation Scrap Ratio at Sachet Line

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Improve Operation Scrap Ratio at Sachet Line

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QC Circle Activity

PT Kao Indonesia - Factory

Improve operation scrap ratio at

Team: SEMUT HITAM

Copyright © 2007 KAO CORPORATION. All rights reserved. 1

Promoter Hendra A./Andy B./Irwan H.

Adviser Oka/Okamoto Secretariat M. Istari/Gulut H.

Team work 8 step 7 tools Idea

Bayhaqi Andi Momo K Syarkowi Adha N Sutrisno Asmuni Nanang S

Copyright © 2007 KAO CORPORATION. All rights reserved. 2

2 Quality Issue 2006: 9 Customer Complaint 2007: 5 Complaint

BRAINSTORMING PARETO BRAIN STORMING

“Improve Operation Scrap Ratio

Net weight of product

amount happened in sachet line

84,5 % of 1,67 bill Rp amount of scrap

If we can reduce 25 %, it means 1 billion rupiah

4 Planning of activity plans

... Reporting as recipe,

-Volume of Measuring cup change due to

Std vs Actual Scrap Line 1

Actual scrap (%)

Actual Scrap Standard Scrap

No method Current daily

Grasping / reporting consumptions as BOM (recipe)

FHC Tooled with new

1.A Study & develop new method: Nuryanta JUL

1.A Study & make new method: Nuryanta JUL

Measure powder Cost 5

Discharged powder Total 13

1.A Study & develop new method: Nuryanta AUG

1.A Study & develop new method: Nuryanta AUG

Manual activity combined with data taken

2 Stopper position standardization: to be (3 mm) Bayhaqi, Aug

Standard vs Actual Scrap ratio (% )

Starting New method

Scrap ratio After Implement New grasping powder Before:

Countermeasure Actions are EFFECTIVE!

Scrap ratio FHC Packing

Continuing activity from 1st QCC

-Volume of cup change due to

Sample of Inacurat Sample weight of FHC Improve new

Time to time operational to

Operator used control chart to monitor average of weight, so

Easy to eye catch, then quick action taken

Describe clearly with picture

Clearly task guide operator to do

CHECK: Step 7:Confirmations of Effectiveness

Effect / Counter- Due

Inacurat Computing Improve new

CHECK: Step 7:Confirmations of Effectiveness

CHECK: Step 7:Confirmations of Effectiveness

Scrap ratio of FHC Sachet Line

1.5 Before QCC Activity

CHECK: Step 7:Confirmations of Effectiveness

STD Consumption STD Consumption

ACT Consumption STD Consumption

P&A Overhead SCRAP

Volumetric Cup problems Register Form As ISO

QCC Level Skill of member QCC Level Skill of member

Bayhaqi asmuni Bayhaqi asmuni

Team work 8 step 7 tools Idea

Wheels PDCA cycle, by continuing QCC Activity with next theme: