8/16/2019 Galih Aprianto 55115110113

1/8

ANTI CHIP APPLICATION :

WASTE REDUCTIONcontent :

prepared by :

BACKGROUND

IMPROVEMENT RESULT

ATTACHMENT

January, 16 th 2015PT General Motors Indonesia Manufacturing

Bekasi Plant

-behalf of Primer Coat Team-

Galih Aprianto

8/16/2019 Galih Aprianto 55115110113

2/8

BACKGROUND

Anti Chip Coatings are applied to protect vulnerable part (which is Rocker Panel) from stone chipping that

can penetrate and damage existing paint and may go all the way to the bare metal panels

Definition

Left Side Right Side

Spec :

Thickness : min 300 mAppearance : Material Applied as Designated in the MPD

Anti Chip

8/16/2019 Galih Aprianto 55115110113

3/8

BACKGROUND(cont’d)

Old Condition

Many Over Spray of Anti Chip left on the cover and floor.It is WASTE

Need to action for eliminating Anti Chip waste

( waste 461 gr/ unit)

over spray (waste)

8/16/2019 Galih Aprianto 55115110113

4/8

IMPROVEMENT

No ItemPicture

RemarkBefore After

1 Reduce GunQuantity

1. Reducing Gun Q’ty / side :2 pcs 1 pcs

2. Make new setting position &adjustment Gun for keepingcoverage coated Anti Chip areaas specification3. This improvement can reducea . over spray/ wasteb . our spare part consumptionof Gun Anti Chip

2 Simplify Anti-Chipcover

Before : Cover must be large, tocover unit from over spray. Needmore effort also for cleaningactivity After : Simple cover because ofminimum over spray. And moreeasy to be cleaned.

#1

#2

#1

8/16/2019 Galih Aprianto 55115110113

5/8

RESULT

No Item Illustration Remark

1 Before(2pcs Gun/ side)

- Placing Gun to new position- Modify guidance tube/bar of handle-arm Gun- Re-setting Gun to keep area coverage

Result :*) Thickness = 300 ~ 400 mm*) Appearance = OK

Note :-- PTR process had been followed-- SOS/JES had been revised & JIT had been completed

2 After(1 pc Gun/ side)

Conclusion : 1 pc Gun Anti Chip per side can give result that meet PCP requirement

judgment : OK

Product requirement

8/16/2019 Galih Aprianto 55115110113

6/8

RESULT (cont’d )

Conclusion : Cost Saving that can be reached about IDR 5,5 million /month

as per unit IDR

1 Anti Chip Material Waste 461 gr/ unit 82 gr/ unit Rp.24,219 /kg 379 gram 5,140,241 Reducing over spray waste

2Gun Anti Chip

(Left & Right)

4 pcs 2 pcs Rp.400,000 /pc 2 pcs 133,333 Reducing RAC tip part change

3 Cleaning time 2.9 min/unit 1.3 min/unit Rp.307.71 /min 1.6 min 275,708 Reducing Non Value Added job

5,549,282

RemarkNo. Item Before AfterSaving / month

Cost (IDR)

Cost Saving

8/16/2019 Galih Aprianto 55115110113

7/8

ATTACHMENT

Confirmation about the spec./ requirement

8/16/2019 Galih Aprianto 55115110113

8/8

Main Role and Executor

1. Udjang Andi Primer Coat Team Leader

2. Wisnu Yugo F Primer Coat Team Leader

3. Andri Saputra Primer Coat Team Member

4. Komarudin Primer Coat Team Member

5. Bayu Kurniawan Primer Coat Team Member

ATTACHMENT