pengetahuan tpm 1
TRANSCRIPT
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8/13/2019 Pengetahuan TPM 1
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OWNERSHIP Through Mini Company & TPM
Pengetahuan TPM 1
TPM
TPMHand Book
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Hand Phone/Pager
Toilet
Jadwal Acara(Waktu) No Smoking
Snack
Pintu Darurat
TATA GRAHA
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Peserta dapat mengetahui apa itu TPM dan pentingnya
implementasi TPM di perusahaan
Sasaran Pelatihan
Peserta dapat mengetahui 8 Pillar TPM
Peserta dapat mengetahui apa itu OEE
Peserta dapat mengetahui tahapan implementasi TPM
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Agenda
Apa itu TPM?
Kenapa TPM?
Preventive Vs Productive Vs TPM
5 Pokok Definisi TPM
Sasaran TPM
8 Pillar TPM
Mengenal OEE
5 Tahap Implementasi TPM
TPM Awards
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Develop Experiential marketing program
Aggressively & systematically develop Marketing
Leaders
Develop B2B Account management (hospital)Build strong brand & corporate image
5
VISIONDriving sustainable growing pharma company enabled by innovation, operation
excellence, and one-culture competent leaders
Winning Goals 10-14Magic FIVE
Innovation
One Culture
Competent Leaders
INNOVATION
Institutionalized
innovation process
(products, services,technology, process,
marketing)
WHAT HOW
Adopt Innovation Principles & Culture
(from corporate)
Define Innovation Framework & Method
Enhance strategic networking
Develop Innovation Infrastucture &
technologyGenerate Innovation Talent Pool
Develop Experiential marketing program
LEADERSHIP
Develop One Culture
Competent Leaders
(Employees as Company
Competitive Advantage)
Recruit best talents
Establish talent pool
Support Kalbe Leadership Center (Pharmacurriculum, etc)
Pharma Competent
leaders traits , Winning
Culture & Winning
Team
6 new blockbuster API
15.000 Improvements
(2014)
5 sites World class
manufacturing
(Certified TGA/PICs,
ISO/OHSAS, Kalbe lean
system)
Revenue: Rp. 5.000 T
CAGR 17%OP 1 24.65% to NS
(Rp.1.232T)
15 Asia & Africa countries
5% MS above second
leader in Indonesia
Customer satisfaction
index (CSI) >75
Collaborative Innovation for Customer
Delight
Driving sustainable
grow
MARKETING & CRM
Increased CustomerLoyalty and Life Time
Value Achieved market
leadership in focused
diseases management
Current State
Future State
Market / consumerrelated1.A Degenerativemarket increasing1.B Booming genericmarket1.CIncreasing demand fornatural/herbalproducts
1.DIncreasingnumberof hospital institutions1.E Governmenthealthspending forpoverty1.F Changein consumerbehavior(DTC, Tech, )Product& technology2.A Theneedforbundledproducts(cross selling)2.B Highadoptionon advancetechnology(DDS, nanotech, bio-tech,
stem cell)Regulatoryrelated3.A Manufacturerratings (GMP)3.B PIC/s, AFTA, ASEAN communityintegration3.CIncreasingneedfor BA/BE requirement
1
1.A Price control1.B Increase RM/PMcost1.CGlobal generic player1.DStricterhealth & pharmaregulations
2.A Growth agilityof the medium size players, especiallythrough :a. NPDb. Pricing strategyc. Service level standardd. Coverage (hybrid model)
Ima g e 1.1 CompanyCredibility1.2 Trusted byMNCslicensor1.3 Strong financialand manufacturingresourcesMarket Leadership
2.1 PharmaMarket Leader2.2 Coverage to all segments.2.3 Wide Range of products and presentation2.4 QualityStandard: cGMP, PICS, ISO, OHSAS
Certified FacilitiesSupply Chain
3.1 End toEnd SupplyChain (physical infrastructure)3.2 High Bargaining / Negotiation Power
Manufacturing Unit Cost1.1IncreasingCOGSSCM & CRM2.1Inefficient & un-integratedbusiness process (SCM, CRM)
SCM: alignment, dataaccuracy dist-principle CRM: noclearCRMblueprint
Human Capital3.1People:
Passion(penjiwaan) Silomentality(sharingresources/opportunity) TobePioneer Challenger(new/biggerchallenges) comfort zone ,needtobechallenged Competency(system thinking, problem solving)Brand Communication
4.1Sales & marketing: as-is:promotionalmaterial& event to-be: full-scale&full-scopemarketing
Productivity5.1GP / Emco5.2MM/ Emco
4-1,2 Brand Communication Market / Consumerrelated, Product&Technology
-(see Health Solution)
-Develop Experientialmarketing / emotional branding- Educate(across relationship assets : channels, endorsers, partners,vendors,distribution and service providers)- Communityof users (endorsers,partnerchannels, consumers)
1-1,2 Manufacturing Unit Cost Market / Consumerrelated, Product & Technology-Develop price movement insight tracking and analysis(refer to Game Theory)
-Deepening loyalty buildinginitiatives with segmented endorsers, fromtransactional orientedinto emotional bounding
-Redefi ne RM/ PM/OEMFG Strategic Sourci ng forselected items to support price competition
3-1,2 HumanCapital Market / Consumerrelated,Product&Technology- Leadership development : program&pl acement fitthrough mentoring (shared &clarity of
objectives) tosupport market /consumer rel ated opportunityabove-Reward system: routinevsstretch
2-1 SCM&CRM Market/Consumerrelated
- One OBJECTIVEtofulfi ll market opportunities, productavailability, customer satisfaction andworking system- Develop demand sensing and shaping more accurately
3-2
Human CapitalCompetitiveAdvantage-DevelopNPDprocess standard (collaborative)
2-2 SCM &CRM CompetitiveAdvantage-Participateas part of systemic End-to-EndSCMteam
1,4-1,2 Manufacturing UnitCost PharmaGlobalization Impacts- Developpricemovement insight trackingandanalysis (refertoGameTheory)-Deepeningloyaltybuildinginitiatives withsegmentedendorsers,from transactionalorientedintoemotionalbounding-RedefineRM/ PM/ OEMFG Strategic Sourcingforselecteditems tosupport pricecompetition
2-2
MarketLeadership CompetitiveAdvantage-DevelopNPDprocess standard (collaborative)
3-2 SupplyChain
CompetitiveAdvantage-Participateas part of systemic End-to-EndSCMteam
2-1 MarketLeadership PharmaGlobalization Impacts- Developpricemovement insight trackingandanalysis (refertoGameTheory)-Deepeningloyaltybuildinginitiatives withsegmentedendorsers,from transactionalorientedintoemotionalbounding-RedefineRM/ PM/ OEMFG Strategic Sourcingforselecteditems tosupport pricecompetition-Implement risk management
PharmaSWOTAnalysis
Strength
Weakness
O pp or tu ni ty T hr ea t
1-1 Image
Market/Consumerrelated
BuildStrongBrand& corporateimage
- Educate(v iadifferentchannels )bothendorsersand consumers
- Community of users
-Bui lds inglev iew consumerdatabase-Grow licenseinrelatedproduc ts /serv ices /technology :
-Roadmap2009-2012
-TCfocus2009:oncology , renal,os teo/remato-Segmentfocus2009: middle&middle-up
-Channel focus2009:community (informationflow)
-Deepeninginnovationfunnel(degenerative,generic , herbal)
-Develop B2BAccountManagement(hospital)2-2 MarketLeadership
Product &Technology
-Leverageandrepos itionDDS
-TCfocus2009:ex is tingDDS produc ts (sales )
degenerativedisease(brandawareness seeseparatefi le)
-Segmentfocus2009: middle&middle-up-Channel focus2009:consultativeandpersonalized(bothdis tributionsales force
andoutlet)
- Speeduppipel inegenerationintheinnovationfunnel- OnePharmapilotingforselec tedTC(seeattachment.)
3-1 SupplyChain
Market/Consumerrelated
- OneOBJECTIVE tofulfil l marketopportunities , produc t avai labil i ty ,cus tomersatis fac tionandwork ingsys tem- Developdemandsens ingandshapingmoreaccurately
1,2-3 Image, MarketLeadership
Regulatoryrelated
-Redefineregis trationprocesss tandard(i .e.: combineownandoutsource/dealmaker)
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Operation Excellence
OPERATIONAL
EXCELLENCE
High value added
operation (efficient &
effective operation)
Lean & Agile SCM
Risk Management
Business Process Reengineering Project:
Map current business process
Benchmark & implement Best Practices
Build culture:
Promote alignment
Manage execution by institutionalizing KMSLeverage relevant technology
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Bagaimana caranya
bisa jadi World Class
Manufacturing Site??
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DENGAN PENERAPAN
TPM(Total Productive Maintenance)
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Apa itu TPM?
Sistem manajemen
perawatan mesin
yang dikeluarkan
oleh JIPM
(Japan Institute of
Plant Maintenance)
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Apa itu TPM?
TOTAL
PRODUCTIVE
MAINTENANCE
Total Efisiensi
Total Sistem Perawatan
Total Keterlibatan
Maintenance Prevention
Maintainability Improvement
Preventive Maintenance
Tanpa Pemborosan
Manajemen perawatan
mesin
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Kenapa TPM?
1. Hasil nyata yang signifikan
Productivity
Quality
Cost
Delivery
Safety
Morale
Environment
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Contoh2 Pencapaian TPM
Kelompok Contoh-contoh Efektifitas TPM
P
(Productivity)
Labor productivity increased:140% (Company M) 150% (Company F)
Value added per person increased:147% (Company A) 117% (Company AS)
Rate of operation increased:17% (68% 85%) (Company T)
Breakdowns reduced:98% (1,000 20 cases/mo.) (Company TK)
Q
(Quality)
Defects in process reduced:90% (1.0% 0.1%) (Company MS)
Defect reduced:70% (0.23% 0.08%) (Company T)
Claims from clients reduced:50% (Company MS) 50% (Company F) 25% (Company NZ)
C
(Cost)
Reduction in manpower:90% (Company TS) 30% (Company C)
Reduction in maintenance costs:15% (Company TK) 30% (Company F)
25% (Company NZ) Energy conserved:
30% (Company C)
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Kelompok Contoh-contoh Efektifitas TPM
D
(Delivery)
Stock reduced (by days):50% (11 days 5 days) (Company T)
Inventory turnover increased:200% (3 6 times/mo.) (Company C)
S
(Safety/Environment)
Zero accidents
(Company M) Zero pollution
(Every company)
M
(Morale)
Increase in improvement ideas submitted:230% increase (36,8/person )
Small group meetings increased:
200% (2
4 meetings/mo.) (Company C)
Contoh2 Pencapaian TPM
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Kenapa TPM?
1. Hasil nyata yang signifikan
Keuntungan
16 Major Losses
NVA
VA
Material + Energy
Keuntungan
NVA
Keuntungan
16 Major Losses
NVA (Non Value Added)
VA (Value Added)
Material + Energy
KONDISIAWAL
Harga
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Kenapa TPM?
2. Mengubah Lingkungan Kerja
BEFORE
Kotor, berdebu, banyak
Oli dan Grease,
kebocoran pipa, dll
AFTER
Lebih 5R, tidak ada
kebocoran, aman,ramah lingkungan
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3. Mengubah Para Pekerja
Meningkatkan motivasi kerja
Meningkatkan Keterlibatan
Kenapa TPM?
OWNERSHIP Through Mini Company & TPM
TPMTPMTPM
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Preventive Vs Productive Vs TPM
PREVENTIVEMAINTENANCE
EFISIENSI
PRODUCTIVEMAIINTENANCE
TOTALPRODUCTIVE
MAINTENANCE
TOTAL SISTEMPERAWATAN :
1. Maintenance
Prevention
2. Maintainability
Improvement3. Preventive
Maintenance
AUTONOMOUS
MAINTENANCE
o o o
o x x
o o x
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(JIPM, 1989, TPM in process Industries, Tokutaro Suzuki, hlm 6)
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SASARAN TPM
ZERO ACCIDENT ZERO BREAKDOWN ZERO CRISIS ZERO DEFECT
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8 Pillar TPM
Fo
cusedImprove
ment
AutonomousMaintenance
P
lannedMainten
ance
T
raining&Education
EarlyManage
ment
(Product&Equ
ipment)
QualityMaintenance
SHE(Safety,Health&
Environme
nt)
5R
OfficeTPM
(TPM
inAdmnistrative
andSupport
Depts.)
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8 Pillar TPM & Sasaran masing2 Pillar
FI AM PM TE EEM
Zero B/D
Zero
defect
Operator
yang
memahami
mesinya
Operatoryang sayang
mesinya
Kegiatan
Perawatan
yang
optimal
dengan
biaya
Memadai
Zero B/D
Kompe
tensi
Operator
dan
Teknisi
yang
lebih
tinggi
Mesin yang
handal,
mudah
dijalankan
dan mudah
dirawat
Operasi
yang stabil
setelah
instalasi
Sasaran
QMTPM in
SupportHSE
Zero
Defect
Support
kegiatan
TPM
Zero
Accident
Zero
Pollution
Peningkatan lapangan dan pengembangan
hubungan manusia dan mesin yang optimal
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Apaan sihOEE OEE adalah singkatan dari Overall
Equipment Effectiveness
Merupakan suatu ukuranefektivitas
operasionalmesin dibandingkan dengan
designmesin
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OEEOk, cukup jelas!
Apa saja komponen
OEE ?
OEE
AV(Availability)
RQ(Rate ofQuality)
PE(Performance)
% OEE = % Availability X % Performance X % Quality
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OEE
AV(Availability)
Kemampuan mesin beroperasisesuai
denganjadwal yang telah direncanakan
PE(Performance)
Kemampuan mesin beroperasisesuai
dengan kemampuan maksimal mesin
RQ(Rate ofQuality)
Kemampuan mesin beroperasidengan
menghasilkan produk yang berkualitas
dalam satu kali proses
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OEEWAKTU OPERASIONAL PABRIK (SHIFT 1510 menit)07:00 AM 15:30 PM
WAKTU KERJA TERENCANA
WAKTU OPERASIONAL MESIN
WAKTU KERJA AKTUAL
WAKTU KERJA EFEKTIF
Istirahat,
Briefing, PM, dll
Breakdown,SUCU, dll
Reduce Speed,
Minor Stop
Reject,
Yield Loss
AV
PE
RQ
% AV = Waktu Operasional Mesin X 100%
Waktu Kerja Terencana
% PE = _____________Output Aktual__________ X 100%
Waktu Kerja Aktual X Standar Output/menit
% PE = Good Output X 100%
Output Aktual
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Trus, Bagaimana cara
implementasinya ???
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Bagaimana Cara ImplementasinyaPhase 0 Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
Pre-Planningfor Pilot Line
Pilot Lines Activity Planning forTPM MasterPlan
Roll-out firstanniversary
fully Implementedand upgraded
TPM Award Year
3months to
6months
6months to 12months 3months to
6months
12months 12months to 24months 12months
1 Official statement of TPM
2 Introductory training
3 Promotion and organization of TPM
4 Policies and guidelines
5 Preparation of master plan
6 Kick-off
7 Efficient production structure
7-1 Focused Improvement
7-2 Autonomous Maintenance
7-3 Planned Maintenance
7-4 Training & Education
8Quality Maintenance
9Systematize management of
8pillarsEarly Management
Office TPM
SHE (Safety, Health and Environment)
10
11
12 Raise TPM
levels
Ada 5 Tahap Implementasi
Ada 12 Langkah
Tahap 0
2 step
Tahap 1
1 step
Tahap 2
3 step
Tahap 3
2 step
Tahap 4
3 step
Tahap 5
1 step
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TPM Award & Its Level
Level 4: Award For World Class
Achievement
-Volvo, Sony
Level 3: Special Award
-Toyota, Unilever Indonesia
Level 2: TPM Consistent Commitment
Award
-Subaru, Isuzu
3 years
8 Pillar
Step 4
AM
2years
8 Pillar
2years
8 Pillar
Level 1.A : TPM Excellence Award
Category A
- Phillips 66, Motorola
Level 1.B : TPM Excellence Award
Category B
- Sakura Java Indonesia,
Maruhachi Indonesia
2 years
5 Pillar
Step 4
AM
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TERIMA KASIH