10. Modul 10 Pencapaian & Penciptaan Nilai KIK

MODUL 10:

PENCAPAIAN DAN PENCIPTAAN NILAI

PENCAPAIAN DAN PENCIPTAAN NILAI

• MENYATAKAN DAN MENYENARAIKAN FAEDAH, KEBAIKAN,MANFAAT, NILAI DLL YANG DIPEROLEHI DARIPADA HASIL PROJEK

• MENGUKUR NILAI PENCAPAIAN• MEMBANDINGKAN ANTARA FAEDAH YANG

DIPEROLEHI DENGAN KOS PERLAKSANAAN• MENGAITKAN FAEDAH PROJEK DAN

SUMBANGANNYA KE ATAS PENCAPAIAN MISI DAN MATLAMAT SYARIKAT

• MENYESUAIKAN SASARAN DENGAN PENCAPAIAN SEBENAR

• PENCAPAIAN DAN PENCIPTAAN NILAI TELAH MENCAPAT PENGIKTIRAFAN DARI DALAM ATAU LUAR ORGANISASI

PENCAPAIAN DAN PENCIPTAAN NILAI (SAMB…)

• KESAN-KESAN KE ATAS PERSEKITARAN, KOMUNITI DAN SOSIALBUKTI PENGESAHAN SEPERTI: SURAT PENGHARGAAN, SURAT PENGIKTIRAFAN, ANUGERAH YANG DITERIMA, TANDA ARAS, SESI PERKONGSIAN PENGETAHUAN

• PENCAPAIAN DAN PENCIPTAAN NILAI DIKALANGAN AHLI

• EG: CARTA RADAR, SOAL SELIDIK, SENARAI SEMAK• VERIFIKASI DAN PENGESAHAN TERHADAP

PENCAPAIAN DAN PENCIPTAAN NILAIBUKTI PENGESAHAN:BAHAGIAN KEWANGAN, JURU AUDIT, SIRIM DLL

CONTOH

18

90

10

3

1

2

5

120

60

19

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

NCL

LATHE

MILLING 1

CNC

POWER SAW

FITTING

QC

PRO

CES

S

TIME MAN

TIME MC

REDUCE PROCESS STANDARD FROM 8 TO 7 PROCESS

STD. MAKING NCM CHUCK

TIME / MINUTES

6.1 .ACHIEVEMENT AND VALUE CREATION

TANGIBLE BENEFIT

18

90

10

3

1

2

5

120

60

19

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

NCL

LATHE

MILLING 1

CNC

POWER SAW

FITTING

QC

PRO

CES

S

TIME MAN

TIME MC

TANGIBLE BENEFIT

IMPROVED CYCLE TIME FROM 366 MIN TO 328 MIN( 38 MINUTES )

STD. MAKING NCM CHUCK( NEW )

TIME / MINUTES

6.1 ACHIEVEMENT & VALUE CREATION

TANGIBLE BENEFIT

STOP NCM SETTING TIME LOST AT CUTTING SHOP

ZERO SETTINGDEFECT

1.5 HR = IS A STD. STTING TIME FOR NCM MACHINE BASE ON PIS.

129

86

125112

126 122 117

10 8 15 9 8 10 10

020406080

100120140160180200

MONTH

Output

Reject

Output 129 86 125 112 126 122 117

Reject 10 8 15 9 8 10 10

%

Sept 04 Oct 04 Nov 04 Dec 04 J an 05 Feb 05 AVE

REJECT10PCS/MONTH


SETTING TIME LOST1.5 HRS x 10 PCS =15 HOURS

ZERO DEFECT SETTING AT

NCM MACHINE

SAVING 15 HRS/MONTH

MATERIAL REJECT COST SAVING

(PROCESS HR + RAW MTR ) X REJ.QTY X 12( 6.1 X 11.7 X 3.8 = RM 271.2 + 22.5 ) X 10 X 12( 271.2 + 22.5 = RM 293.7 ) X 10 X 12

= RM 35,244.00/yrNCM SETTING SAVING

STD.SETTING TIME ( PIS ) X MANAGERS RATE X EXCHANGE RATE X REJECT QTY X 12.1.5HR X 11.7 X 3.8 X 10 X 12

= RM 8,002.80/yrPROCESS IMPROVEMENT ( SAVING TIME )

PROCESS HOUR SAVING ( IMPROVE ) X MGR.RATE X EXCHANGE RATE X 1231 MINIT X 116.7 = 3618 MINIT / 60 = 60.3 HOUR60.3 HOUR X 11.7 X 3.8 = RM 2680.9 X 12

= RM 32,171.30 /yr

OTHERS CHUCK PROCESS TIME SAVING

NOTE : USD 11.7 IS A EPSON RATE ( MANAGERS RATE ) TO CALCULATE COST PER HOUR.

SLITTING SAW USAGE SAVING

AVEARAGE USAGE (MONTH) X UNIT PRICE15 X 151.65 = RM 2274.75 X 12

= RM 27,297.00/yr

TOTAL SAVING PER YEAR

A + B + C + D + E

COST INCURRED

RM317,610.00-

RM 2,145.5

QUANTUM OF ACHIEVEMENT


RM 315,464.50/yr

-

1) SMART JIG ( 6 ITEMS ) RM 1195.602) NCM SINGLE SETTING JIG RM 160.003) QC NCM CHECKING JIG RM 58.504) AMADA COOLANT RM 598.405) POWER SAW BLADE RM 133.00

TYPE OF CHUCKPROCESS HR

IMPROVEAVE. QTY /MONTH

TOTAL TIME (MIN)

BOW CUTTING CHUCK 31 min 82 pcs 2548.20

MIRROR CHUCK 20 min 222 pcs 4440.00

BUFFING CHUCK 20 min 210 pcs 4206.00

NCL CHUCK 31 min 95 pcs 2954.30

OTHERS 31 Min 322 10021.7

24170.2 / 60 = 402.8 hour TOTAL 24170.20

402.8 X 11.7 X 3.8 = RM 17910.12 X 12 = RM 214,921.4

COST OF PROJECT

108

15

98

1011

6

0 0

129

86

125

112

126122

106

121125

97

0

2

4

6

8

10

12

14

16

18

20

22

24

0

20

40

60

80

100

120

140

Reject Output

Reject 10 8 15 9 8 10 11 6 0 0

Output 129 86 125 112 126 122 106 121 125 97

Sept 04

Oct 04

Nov 04

Dec 04

J an 05

Feb 05

Mac 05

Apr 05

May 05

J un 05

J uly 05

REJECTQTY

(PCS)

OUTPUTQTY

(PCS)

MONITORINGDATA UNTIL

13/6/2005


RECONCILIATION OF THE TARGET

DATA COLLECTED DURING MONITORING

6. IMPLEMENTATION OF THE INNOVATIVE SOLUTION

16~20 MAY 16 ~ 20 MAY

16 ~ 18 MAY

Quality Monitoring At CNC Machine

Quality Monitoring At Power SawMachine

Quality Data For Off Center check

Time Study At Power Saw Machine.

NEW COOLANT – AMADA CUTTING SYNTHETIC SD

66% WATER BASE

ORGANIC ANTIRUST

IT CAN MOVE TO ATMOSPHEREAND SOIL ENVIRONMENT.

SAFE FOR ENVIRONMENT

SHELL TONNE OILS

ENVIRONMENT HAZARD :

Not Ready biodegradable Expected to have a high

Potential to Bio cumulate..

ENVIRONMENTAL / SOCIAL IMPACT

6.5. ACHIVEMENT & VALUE CREATION

NETWORKING

0

6

12

45

3

TEAM WORK

BEFORE START PROJECT

1. VERY POOR

2. POOR

3. GOOD

4. VERY GOOD

5. EXCELLENCE

6. VERY EXCELLENCE

INVOLVEMENT

PLANNINGIMPROVEMENT

EXCELLENT

2 3 4 5 60

POOR

1

Understanding the QCC concept & toolsUnderstand the technical and Engineering knowledge.

Confidence with the idea/ Suggestion givenConfidence project Will success

Commitment to the project.Commitment to group increase

Manage to enhance working Relationship with various groupHigh interactions with external QCC team.

Involvement in learning new Thing.Involvement in dealing with User/others dpt.Involvement in problem solving.

Together analysis the problemData collectionUnderstanding the group

TEAM WORK KNOWLEDGE OF QCC

CONFIDENCE COMMITMENT NETWORKING

COMMITMENT

CONFIDENCE

KNOWLEDGE OF QCC

RONI

DIANA

NORLIDAH

INVOLVMENT

BEFORE BEFOREBEFORE BEFOREBEFORE BEFOREAFTER AFTER AFTER AFTER AFTER AFTER

3 2.5

3

3 2.5

2.5

4

4

4

2.5

2.5

2.5

3

3

3

3

3

3

AVERAGE

5

5

5

5

5

56

6

6

6

66

6

6

6

5

5

5

5

3334 6 665 52.5 6

SOURCE : SURVEY FEEDBACK FROM

AFTER PROJECT

SELF- EXAMINATION

SELF ASSESSMENT RADAR CHART

KAMAL 4 4 44 445.5 5.5 5.5 6 6 6

6.6. ACHIVEMENT & VALUE CREATION

6.7.ACHIEVEMENT & VALUE CREATION

VERIFICATION AND VALIDATION

78

CUTTING SHOP

CUTTING MANAGER THEME COMPLETION( BUSINESS PLAN REPORT)

DEPARTMENT MGR.

CONGRATULATIONS !!!!

CONGRATULATIONS FOR YOUR ACHIVEMENT!!!

RESULT MONITORING AFTER IMPLEMENTATION6. IMPLEMENTATION OF THE INNOVATIVE SOLUTION

11

8

20

29

18

14

0

5

10

15

20

25

30

35

FREQUENCY

0.0050- 0.0094 0.0095 - 0.0194 0.0195 - 0.0294

0.0295- 0.0394 0.0395 - 0.0494 0.0495 - ONWARDS

LCL UCL

0.0000 0.050CLASSES BOUNDRY

RANGE OFTHE PRODUCT

CHECK ITEMS : INNER SITTING DIAMETER VS TOP PROFILE.NO. OF SAMPLE : 100PCS.

NAME OF PRODUCT : NCM CHUCK

HISTOGRAM – OFFCENTER CHECK

6

13

37

20

15

6

0

5

10

15

20

25

30

35

40

46.0015 - 46.0044 46.0045 - 46.0074 46.0075 - 46.0104

46.0105 - 46.0134 46.0135 - 46.0164 46.0165 - 46.0194

46.0195 - ke atas

UCL

46.0000 46.0200

LCL

RANGEOF THE PRODUCT

CLASSES BOUNDARY

ONWARDS

CHECK ITEMS : INNER SITTING DIAMETER

HISTOGRAM OF INNER SETTING DIAMETER.

FR

EQ

UE

NC

Y

46.000 - 0.000+ 0.020

RANGE OF THEPRODUCT

NAME OF PRODUCT : NCM CHUCK

NO. OF : 100PCS.

HISTOGRAM

NORMAL DISTRIBUTIONUNDER CONTROL.

54 4

7

5 56

3

0 0 0 0 0

52

61

53

72

5256

70 71 70

65

7068

62

0

2

4

6

8

10

12

14

16

18

20

22

24

0

10

20

30

40

50

60

70

80

Reject Output

Reject 5 4 4 7 5 5 6 3 0 0 0 0 0

Output 52 61 53 72 52 56 70 71 70 65 70 68 62

Sept 04

Oct 04

Nov 04

Dec 04

J an 05

Feb 05

Mac 05

Apr 05

May 05

J un 05

J uly 05

Aug 05

Sep 05

Oct 05

REJECTQTY

(PCS)

OUTPUTQTY

(PCS)

MONITORING RESULT AFTER IMPLEMENTATION

10. REVIEW & CONTINUOUS IMPROVEMENT

RESULTUNTIL AUG.05

10

4.7 4.2 4 3.52.3

34.8

51.2

65.9

79.8

92.0

100

02468

10121416182022242628

NC

M C

HU

CK

OFF

SE

T

BU

FFIN

G/M

IRR

OR

CH

UC

K R

EJ.

PU

NC

H/D

IED

ELA

Y

CU

TTE

RB

RO

KE

ND

CO

VE

RIN

G J

IGW

EA

R O

FF

MA

TER

IAL

CR

AC

K

PROBLEM

RE

J.Q

TY

0

10

20

30

40

50

60

70

80

90

100

REJECT QTY ACC

54

3 32

002468

10121416182022242628

PU

NC

H/D

IED

ELA

Y

CO

VE

RIN

G J

IGW

EA

R O

FF

CU

TTE

RB

RO

KE

ND

MA

TER

IAL

CR

AC

K

BU

FFIN

G/M

IRR

OR

CH

UC

K R

EJ.

NC

M C

HU

CK

OFF

SE

T

PROBLEM

RE

J.Q

TY

REJECT QTY ACC

BEFORE AFTER

AVERAGE REJECT / MONTH

PARETO GRAPH – BEFORE AND AFTER

PROJECT

30

20

0

10

80

5060

40

70

10090

%

29.4

70.5

88.1100

52.9

REJECT DATA MAY 05

100%ELEMINATE NCM CHUCK OFFSET

10. Modul 10 Pencapaian & Penciptaan Nilai KIK

Education

Transcript of 10. Modul 10 Pencapaian & Penciptaan Nilai KIK