GEMBA MANAGEMENT

Quality
Control
Circle

Policy
Management

Suggestion
System

Standardization
&
Quality Assurance

CrossFunctional
Management

Daily
Management

5S

1/15

Gemba Management in
Company Management
TOP
MANAGEMENT
MIDDLE
MANAGEMENT
SUPERVISOR
FOREMAN &
OPERATOR

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GKM
3S
5R

a sy
t
n
ai ent
M rr
cu

2/15

5R IMPLEMENTATION

WAY TO DEVELOP
WORLD CLASS COMPANY CULTURE

5S

5C

5R

5P

Seiri

Clear-out

Ringkas

Pemilahan

Seiton

Classify

Rapi

Penataan

Seiso

Cleaning

Resik

Pembersihan

Seiketsu

Conformity

Rawat

Pemantapan

Shitsuke

Custom

Rajin

Pembiasaan
3/15

5R IMPLEMENTATION
OBJECTIVES
To create a comfortable workplace and
interesting job
To train employee independently organize
his/her work
To enforce discipline is using standard
To create Visual Factory
Create positive image upon customer view

4/15

EFFECT ON 5R
IMPLEMENTATION
Minimize the potention of:
Accident
Breakdown
Cost
Defect
Increase efficiency and work motivation
A ready organization for transformation in
direction of Top management strategy
5/15

TRANSFORMATION:

BEHAVIOR & WORKPLACE CONDITION

TRAINING

Attitude

Behavior

Workplace

5R IMPLEMENTATION
Culture

Attitude

Customs

Behavior

Workplace

( 3 principles : Consistency, Continuity & Simplicity)

6/15

SUGGESTION SYSTEM
Definition
Management system that involves
every customer in improving quality
through individual suggestion for
improvement

7/15

SS DEVELOPMENT IN JAPAN
(1984)

THE BIG TEN GROUP IN SS IMPLEMENTATION

Matsushita (Panasonic)
Hitachi
Mazda
Toyota
Nippondenso
Mitsubishi Motors
Nissan Motor
Aisin Seiki
Bridgestone Tire

Japan National Railway

6.58
4.65
3.06
2.15

million
million
million
million
1.43 million
1.12 million
1.07 million
0.97 million
0.95 million
0.78 million
8/15

SS IN TOYOTA MOTOR CORP.

(1984)

Number of suggestion : 2.1 million

Number of suggestion/ employee :
40
Participation level: 95%
Acceptance level:
95%
9/15

COMPARATIVE STUDY ON SS DEVELOPMENT

IN AMERICA AND JAPAN (1989)
USA

Japan

Number of people implementing SS 282

666
Number of employee involved
8.642.269
1.646.960
Number of suggestion accepted
996.694
60.343.937
Number of suggestion /100 employee
12
3.664
Number of employee suggest /100
employee
9
75
Adoption rate
32%
87%
Rerata award/adoption
$602.15
$2.20
Rerata economy/adoption
$6.114
$110
Economy/ 100 employee
$22.825
$365.656

10/15

THE DIFFERENCE OF SS
WEST VERSION AND JAPAN VERSION
West (America)

Japan

Emphasize on
economical
output( great ideas)

Emphasize on
participation (small
ideas)

Extremely put
emphasis on Financial
incentive

Psychological Incentive
(pengakuan dan
aktualisasi diri)

Personal motivation

Personal motivation
and group

SS Committee
responsibility

Top management
responsibility
11/15

SS OBJECTIVES IN MANAGEMENT
Suggestion system ideas can be directed for:
Ideas to increase sales
improve servicing, product image, product selection,
exhibition method, etc
Ideas to lower cost
efficient work, reduce non-quality product; overtime
work, wastes; inconsistency; etc

12/15

SS IMPLEMENTATION STRATEGY AND MECHANISM

System
Organization
Regulation

Mechanism Reward System

Standard
Evaluation

Suggesti
on

Suggestion Form

system
Strategy

Education and Training

Campaign
Promotion activity
Motivation
encouragement
Coaching and
Counseling

13/15

QUALITY CONTROL CIRCLE

Definition

Group consist of operators with specific

job who meet together periodically to
discuss and solve problems and the job
environment with focus on improving
quality using quality control system

14/15

QUALITY CONTROL CIRCLE

OBJECTIVES
Improve problem- solving ability
Increase involvement of employee in problem
solving
Promote teamwork in the group
Increase awareness of problem prevention
Increase employee motivation
Increase communication in the group
Improve Top-Bottom relationship
improve quality
15/15