Pengetahuan TPM 1

8/13/2019 Pengetahuan TPM 1

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OWNERSHIP Through Mini Company & TPM 1

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)

-

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??


7/30OWNERSHIP Through Mini Company & TPM

DENGAN PENERAPAN

TPM(Total Productive Maintenance)



Apa itu TPM?

Sistem manajemen

perawatan mesin

yang dikeluarkan

oleh JIPM

(Japan Institute of

Plant Maintenance)



Apa itu TPM?

TOTAL

PRODUCTIVE

MAINTENANCE

Total Efisiensi

Total Sistem Perawatan

Total Keterlibatan

Maintenance Prevention

Maintainability Improvement

Preventive Maintenance

Tanpa Pemborosan

Manajemen perawatan

mesin



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?


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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OWNERSHIP Through Mini Company & TPM 30

TERIMA KASIH

Pengetahuan TPM 1

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