weekly loss zero activity report let’s be no.1 value innovation contents 1. root cause problem...
TRANSCRIPT
Weekly Loss Zero Activity ReportLet’s Be No.1
Value Innovation
Contents
1. Root Cause Problem Summary
2. Root Cause Problem
Attachment : One Point Improvement
(W1 June - Root cause Problem)
Reporter : Dicky Gobel
LGEIN / SSG AV Group
2007. 06. 8
Great Company Great People LGEIN2 / 17
1. Root Cause Problem Summary
No. Area
Problem Status
PIC RemarkProgress Complete Not Complete
1. Document Part 0 11 0 Agung W
2. Logistic Part 0 4 0 Eko Irawan
3 Production Management Part 0 0 0 Ari Bowo
T O T A L 0 15 0
Summary
ITEMWeekly - June Monthly
W1 W2 W3 W4 Total Mar Apr May Jun Jul Avg
Employee (E) 25 25 25 25 25 34 33 33 25 33
Complete (C) 15 15 66 15 66
Ratio (C/E) 60% 60% 200% 200%
Progress (P) 0 0 11 0 11
Total (C+P) 15 15 77 15 77
W1 - June
Ratio Target (C/E) : 200% every month
Great Company Great People LGEIN3 / 17
2. Root Cause Problem
Problem List
No Date Waste/Loss Problem Issued by PIC/DIC Status
1 2 Jun ‘07 No control process for daily container manifest. Agung W Agung W Complete
2 2 Jun ‘07 Invoice number changes suddenly. Agung W Agung W Complete
3 1 Jun ‘07 Mix up Export document, Hasan Agung W Complete
4 1 Jun ‘07 No special case for paper clip. Hasan Agung W Progress
5 2 Jun ‘07 Reduce document Sending Progress report lead time Yan S Agung W Complete
6 2 Jun ‘07 Reduce Estimating Freight Cost Report lead time Yan S Agung W Complete
7 1 Jun ‘07 Daily Forecast Sales Amount progress Merah Eko Irawan Complete
8 1 Jun ‘07 No Special Monitoring Maximize Loading Container Ratio Merah Eko Irawan Complete
9 1 Jun ‘07 No monitoring for Extend Closing Anggun Eko Irawan Complete
10 7 Jun ‘07 To many document shipment by DHL for PHILLIPS buyer Haris Agung W Complete
11 7 Jun ‘07 No Grouping of Shipping Document Haris Agung W Complete
12 7 Jun ‘07 No box for keeping the stamps Widada Agung W Progress
13 2 Jun ‘07 Problems criteria to analyze main problems Anggun Eko Irawan Progress
14 2 Jun ‘07 No monitoring on DHL shipment activity Pedro Agung W Progress
15 2 Jun ‘07 Standard format report for all member Yan S Agung W Progress
Great Company Great People LGEIN4 / 17
Attachment 1 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Document Part Document Part 2-6-2007 2-6-2007
• No Control Container Manifest.• Container and seal numbers in the
System not update.
Out container evidence (P.E.) should be checked and un-match data will be updated by one person (PIC : Agung W).
Control Container Manifest
CustomClearanceCustom
Clearance
….PE flow (after)….PE flow (after)…P.E. FLOW (before)…P.E. FLOW (before)
CustomClearanceCustom
ClearanceDocument
PICDocument
PIC
Checked and update
system
Checked and update
system
Document PIC
Document PIC
By Agung WBy Agung W
Up date Data on M-System
Up date Data on M-System
Great Company Great People LGEIN5 / 17
Document PIC
Document PIC
Attachment 2 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Document Part Document Part 2-6-2007 2-6-2007
• Invoice number changes suddenly• No record of any changes
Changing Invoice monitoring
Should be one PIC for monitoring and recording any changes of invoices. (PIC : Agung W)
Create SI/SRCreate SI/SR **
changeschanges
* : Return M-System, Return doc to Logistic, Record changes..* : Return M-System, Return doc to Logistic, Record changes..
Record any changes of invoice, documents,
and database
Record any changes of invoice, documents,
and database
N/AN/A
Great Company Great People LGEIN6 / 17
Attachment 3 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Document Part Document Part 1-6-2007 1-6-2007
Export Document for clearance mix up between finish documents and progress,
Export documents are separated between finish and progress documents using box file (imco).
Export Document Failing management
Organize filling documents
Organize filling documents
Great Company Great People LGEIN7 / 17
Attachment 4 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Document Part Document Part 1-6-2007 1-6-2007
Disorder paper clips on the table - Create paper clip storage from recycled box
- Placed on the left side of table for easy movement
Paper clip Storage
Orderly, clean, and succinct place of work
Orderly, clean, and succinct place of work
Great Company Great People LGEIN8 / 17
Attachment 5 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Document Part Document Part 2-6-2007 2-6-2007
• 3 hours to prepare the Documents Sending Report preparation.
- Prepare The report using macro system
Reduce Documents Sending Report preparation Lead Time
N/AN/ABEFORE AFTER
3
1
Unit : hours
Great Company Great People LGEIN9 / 17
Attachment 6 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Document Part Document Part 2-6-2007 2-6-2007
4 hours to prepare the freight estimation cost Report preparation
• Prepare The report using macro system.• 1 hours to prepare the report
Reduce Freight estimation cost Report preparation Lead Time
BEFORE AFTER
4
1
Unit : hours
N/AN/A
Great Company Great People LGEIN10 / 17
Attachment 7 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Logistic Part Logistic Part 1-6-2007 1-6-2007
We cant estimate the sales amount in order to achieve the sales target in the 1st, 2nd, and 3rd closing.
• Modify the Production Plan Sheet by adding not only quantity progress but also amount progress daily, so we can estimate our achievement for every closing
Daily forecast sales amount progress report
Sales achievement can be monitor for each closing time
Sales achievement can be monitor for each closing time
N/AN/A
Great Company Great People LGEIN11 / 17
Attachment 8 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Logistic PartLogistic Part 1-6-2007 1-6-2007
• Optimal stuffing not achieve because no monitoring for loading container capacity.
• Create one table to check the result of stuffing and compare it with the reference quantity of each container type.
Maximize Loading container ratio monitoring
N/AN/ABEFORE AFTER
90
95
Unit : %
Great Company Great People LGEIN12 / 17
Attachment 9 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Logistic PartLogistic Part 1-6-2007 1-6-2007
• To high extra cost caused by Extend Closing Problems
• Create monitoring table to control the extend closing monthly and to find out the reason.
Extend Closing monitoring
BEFORE AFTER
90
30
Unit : EA/month
N/AN/A
Great Company Great People LGEIN13 / 17
Attachment 10 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Documents PartDocuments Part 7-6-2007 7-6-2007
• PHILLIPS shipment sometimes using different Ship.Line for one destination
• Documents send by DHL separately.• DHL rate is high
• Send several PHILLIPS documents in to one shipment, in condition the gap between the sending date and onboard date not over than 4 days , and the have same destination
Combine Several documents for PHILLIPS buyer
BEFORE AFTER
175
35
Unit : USD
N/AN/A N/AN/A
Great Company Great People LGEIN14 / 17
Attachment 11 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Documents PartDocuments Part 7-6-2007 7-6-2007
Shipping documents are mix up between documents already receive BL, only receive draft BL, already sales, etc.
• Shipping document should groups into : • Documents with no draft & not sales• Documents with draft BL & Already
sales confirm• Original BL receive & have sent to
buyer
Grouping Shipping Documents
Orderly, clean, and succinct place of work
Orderly, clean, and succinct place of work
Great Company Great People LGEIN15 / 17
Attachment 12 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Documents PartDocuments Part 7-6-2007 7-6-2007
•Stamps are disorder, •Waste time to look for when needed.•Dirty on the tables
• Box storage to store the stamps in one place• Every one who use stamp should return it to
where it belong.
Stamps storages
Orderly, clean, and succinct place of work
Orderly, clean, and succinct place of work
Great Company Great People LGEIN16 / 17
Attachment 13 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Logistic PartLogistic Part 2-6-2007 2-6-2007
No problem category in order to push other related dept. that cause delay on stuffing
• Separate problems in category
Landing cause problem criteria
N/AN/ACategory to find out
where the main problems
Category to find out where the main
problems
Great Company Great People LGEIN17 / 17
Attachment 14 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Documents PartDocuments Part 2-6-2007 2-6-2007
• No monitoring on DHL shipment Activity.• No shipment date report for buyer.
• Create daily Historical Shipment by Air waybill DHL, contain :
• No Air waybill• Invoice no• Date of shipment• destination
DHL shipment monitoring
N/AN/ADaily DHL tracing for
buyerDaily DHL tracing for
buyer
Great Company Great People LGEIN18 / 17
Attachment 15 : Root Cause Problem (Finish Project)
◆ Loss Zero Activity ◆
Before After Quantitative Result
Qualitative Result
Div/Group
Area Date
TitleWaste/Loss
Type
Problem Improvement Activity
Remark
□ Defect □ Transportation □ Over Production □ Waiting
□ Processing □ Movement □ Inventory
Model Line
AV - Sales Support GroupAV - Sales Support Group
Documents PartDocuments Part 2-6-2007 2-6-2007
No competition among each Documents PIC in order to optimalization their works
• TDR team create one format of groups performance report to each PIC, contain :
• Performance of each PIC• Groups goals and achievement• Issue
Standard format for member performance
N/AN/AIncrease PIC performanceIncrease PIC performance