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11_Skill Matrix_Multiskill Development & Training plan.pdf

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Aji Wijaya Kusuma

The document provides information on creating a skill matrix and training plan for employees. It includes a sample skill matrix that assesses employees' current capabilities for various processes on a scale of 1-10. A multi-function worker training sheet is presented as a template to track individual employees' skill development over time for critical processes. The training sheet includes fields to track performance needs, manpower needs, and results of training for beginning, middle and end of year. Instructions are provided on steps to identify critical processes, assess skill levels, determine ideal staffing needs, and calculate total employee capabilities.

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General Information Skill Matrix, Multi Skill Development & Training Plan
General Information Goal Mampu membuat Skill Matrix & Rencana Training
General Information Coach’s Background AJI WIJAYA KUSUMA, ST Enthusiast & professional on Lean, Improvement, people development and motivation. 16 years experience in Apparel Industry focus on practical lean implementation, costing & capacity management 471.wijayakusuma@gmail.com +62 815 7898 6913 Aji Wijaya Kusuma Lean Manufacturing Industrial Engineering Production Planning Apparel CMT Costing & CPM 90% 90% 80% 85% 85% Supplier Capacity Management https://www.youtube.com/user/471WijayaKusuma/featured https://www.facebook.com/Lets-LEAN-788239307962079
General Information Masalah Pabrik Garment
General Information Layout lama ± 1-2 hari Mesin belum siap pakai Skill operator belum OK Kalo sore sisaan permakan masih ada
General Information Training Within Industry Perang Dunia Ke-2
General Information Q1 Q2 Q3 Q4 1 2 2 5 3 6 4 1 1 2 2 2 2 1 GREENTEX LEAN DEPT-- SKILL MATRIX & TRAINING PLAN SKILL NAME /PROCESS 1. Motion & Time Study 4. Presentation 3. 5S & Visual Performance 7. Problem Solving PDCA 2. Data Analyze & Visualization 5. Coaching 6. Inter Dept Relation REMARKS ACTUAL CAPABILITIES (75% PERFORMANCE) Manpower Needs Performance Needs (Work Manner) No. Reni 5 6 7 Riski Chairani NO SKILL KNOW THE THEORY CAN APPLY SOME OF THE THEORY HAVE APPLIED IN MOST OF ACTUAL PROBLEM CAN COACH OTHER WITH PROVEN RESULT Winarsih Putut Setiawan Remarks Job Needs (Poduction Change) RESULT OF TRAINING Beginning of Year Middle of Year End of Year SKILL LEVEL TARGET LEAN TEAM NAME
General Information Remarks Job Needs (Poduction Change) End of Year Middle of Year RESULT OF TRAINING Beginning of Year 4 3 WATI 2 IKA 15 1 TINA ACTUAL 10 3 2 6 52 6 2 5 3 5 3 TARGET TOTAL OPERATOR 10 5 5 2 No. CAPABILITIES Manpower Needs Q1 Q2 Q3 Q3 Performance Needs (Work Manner) JOIN WB CROSS BOX JOIN HOOD SNAP/BARTACK PASANG PLACKET PASANG ZIPPER OVERDECK MAKE UP OVERLOCK SKILL MATRIX SEWING Name: Section/Group: Date: Process or Operation Name PENGUASAAN MESIN PENGUASAAN PROSES SPESIAL REMARKS SINGLE NEEDLE DOIBLE NEEDLE TARGET SKILL NAME
General Information Creating a Planning Time-table MULTI-FUNCTION WORKER TRAINING TIMETABLE Name: REMARKS Section/Group: CAPABILITIES Date: NUMBER NAME 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. = 100% Performance = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks
General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 5/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Forming Grinding Punching Seam Weld Edge Prep Tacking Spot Weld Flange Weld Paint KEY Increase orders 10% for the year Primer Step 1 Step 2
General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 5/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Forming Grinding Punching Seam Weld Edge Prep Tacking Spot Weld Flange Weld Paint KEY Increase orders 10% for the year Primer Step 3 List Job Names
General Information 1. Select Critical/Special Process/Machine Line Style SKETCH Proses critical Jenis mesin OUTPUT QUALITAS Namaoperator NIK Cross box Jarum 1 V V Saenur GIU0494 Obras pasangtangan Obras benang4 V Witri GIU2351 Obras variasi samping Obras benang4 V - Tutup kerah Jarum 1 V V Khomsiyatun GIU2088 Stick armhole Kamput V V Drsini GIU0971 Cross box Jarum 1 V V Mila GIU3636 Hemmingtangan Kamput V - Tutup kerah Jarum 1 V V Heni GIU0273 Cross box Jarum 1 V V Masriah GIU0277 Pasangkerah Jarum 1 V V Siti GIU1956 Stick slit Jarum 1 V V Biut GIU3783 Hemmingtangan Kamput V V Suhartiningsih GIU0758 Stick armhole /printing Kamput V Rohani GIU0290 Make up Make up V V Risna GIU0354 Obras kerah Obras benang4 V V Nuraini GIU0337 Stick zipper Jarum 1 V V iis GIU0210 Tutup kerah Jarum 1 V V Elis GIU4130 Pasangzipper Jarum 1 V V Mimin GIU0217 Pasangzipper Jarum 1 V V Uli GIU3204 Stick zipper Jarum 1 V V - Corongtape kerah Jarum 1 V V - Stick tape Jarum 1 V V - Stick zipper Jarum 1 V V Kiswati GIU2461 8 385FA 395FA 2 395FA 12 7 5 P31142 MSTR08390 DATA CRITICAL PROSES SEWING POLO 6 15 16
General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 5/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Forming Grinding Punching Seam Weld Edge Prep Tacking Spot Weld Flange Weld Paint KEY Increase orders 10% for the year Primer Step 4 Assess Skill Levels
General Information SKILL LEVEL PERSENTASE C 1%-25% Hanya dapat melakukan langkah-langkah dasar, dan masih belum lepas dari pengawasan B 26%-50% Dapat melakukan pekerjaan dengan aman, sesuai dengan kualitas yang diinginkan tapi belum mencapai target waktu yang ditetapkan. Masih membutuhkan banyak pengawasan S 76%-100% Tidak membutuhkan pengawasan dan dapat melatih karyawan lain untuk melakukan proses sewing yang ditargetkan A 51%-75% Dapat melakukan pekerjaan dengan aman, sesuai dengan kualitas yang diinginkan dan mencapai target waktu yang ditetapkan. Hanya butuh sedikit pengawasan SIMBOL KETERANGAN
General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Step 5 Ideal number: the ideal number of people capable of doing the job at 75% performance or better
General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Step 6 Step 6 Add Total Capabilities
General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Performance needs: • Individual adherence to quality, rate and safety standards • Individual use of equipment and machines • Waste, rework, damage to equipment and injuries Step 8 Step 7 Manpower needs: • New employees • Promotions / transfers • Vacations • Temporary employees • Job rotations • Temporary assignments
General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Production needs: • Work that piles up • Seasonal work • Bottlenecks • New Work • Production changes Step 9
General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Compare : • IDEAL CAPACITY to • RESULT OF TRAINING Examine : • Manpower Needs • Capabilities and • Job Needs to determine training needs. Step 10 Step 10 • Plan for and record anticipated training completion dates. • Write dates next to individual circles. Step 11
General Information Copyright 2001 - 2008 Lean Associates, Inc.
General Information Line Style SKETCH Proses critical Jenis mesin OUTPUT QUALITAS Nama operator NIK Cross box Jarum 1 V V Saenur GIU 0494 Obras pasang tangan Obras benang 4 V Witri GIU 2351 Obras variasi samping Obras benang 4 V - Tutup kerah Jarum 1 V V Khomsiyatun GIU 2088 Stick armhole Kamput V V Drsini GIU 0971 Cross box Jarum 1 V V Mila GIU 3636 Hemming tangan Kamput V - Tutup kerah Jarum 1 V V Heni GIU 0273 Cross box Jarum 1 V V Masriah GIU 0277 Pasang kerah Jarum 1 V V Siti GIU 1956 Stick slit Jarum 1 V V Biut GIU 3783 Hemming tangan Kamput V V Suhartiningsih GIU 0758 Stick armhole /printing Kamput V Rohani GIU 0290 Make up Make up V V Risna GIU 0354 Obras kerah Obras benang 4 V V Nuraini GIU 0337 Stick zipper Jarum 1 V V iis GIU 0210 Tutup kerah Jarum 1 V V Elis GIU 4130 Pasang zipper Jarum 1 V V Mimin GIU 0217 Pasang zipper Jarum 1 V V Uli GIU 3204 Stick zipper Jarum 1 V V - Corong tape kerah Jarum 1 V V - Stick tape Jarum 1 V V - Stick zipper Jarum 1 V V Kiswati GIU 2461 8 385 FA 395 FA 2 395 FA 12 7 5 P31142 MSTR08390 DATA CRITICAL PROSES SEWING POLO 6 15 16 2. Select Best Operator To Do TOT (Training Of Trainer)
General Information 3. Train the best operator with Lean Method (JI) www.themegallery.com Company Logo
General Information
General Information
Perbaikan Terus-Menerus ❖ Update Weekly/Monthly untuk Skill Level % ❖ Merencanakan lebih awal jika ada resign dan rotasi ❖ Memperbaiki ISQ/RFT Factory Category Level - HR Data S A B C 5% 25% 40% 30% IY 01 12.4% 29.7% 34.5% 18.4% IY 02 6.6% 17.0% 36.1% 26.1% IY 03 7.9% 26.1% 35.7% 26.3% IY 04 9.1% 27.5% 38.2% 21.4% IY 05 9.1% 29.8% 28.5% 24.0% IY 07 7.5% 31.4% 29.7% 19.8% IY 08 7.3% 21.4% 36.8% 22.0% IY 09 4.8% 15.1% 37.4% 29.2% IY 10 6.0% 21.8% 40.3% 23.1% IY 12 4.3% 21.1% 35.5% 25.6% IY 13 6.9% 20.9% 33.9% 20.0% IY 14 11.1% 36.1% 21.7% 23.4% OUTSOLE 0.0% 34.8% 35.9% 4.0% TOTAL 6.5% 25.9% 34.4% 20.3%
11_Skill Matrix_Multiskill Development & Training plan.pdf
Train for mechanic development Test Skill
Visual Control Mechanic Development Skill No NAME Machine Problem Focus Analyze Std Total Time Setting + repair (Minute ) Education Skill Update: 19 Feb Update: 26 Mar Update: 16 Apr Update: 11 Mei Update: 3 Jun Update: 15 Jun Update: 07 Jul Update: 10 August Update: 19 Feb Update: 26 Mar Update: 16 Apr Update: 11 Mei Update: 3 Jun Update: 15 Jun Update: 07 Jul Update: 10 August 1 Dendi Overdeck ( 3 Neddle, Cutt ) Jumping Stitch 3,7 3,8 3,9 3,6 3,7 3,9 20 2 Tatang 3,7 3,7 3,8 3,8 3,4 3,6 3,6 3,7 3 Aji 2,0 2,6 3,6 3,0 2,9 3,3 4 Jenal 3,3 3,7 3,7 3,3 3,4 3,7 5 Andre 3,1 3,3 3,7 3,3 3,3 3,4 6 Hari 4,0 4,0 3,9 3,9 7 Willy 2,8 3,1 3,2 2,7 2,7 3,0 NOTE SCORE REMARKS 0 Can not repairing machine 1 Can carry out basic repairing machine 2 Can carry out basic repairing machine + requires intermediate supervision 3 Can carry out basic repairing machine + requires advance supervision 4 Can carry out basic repairing machine , propose improvement ideas, be able to work with other Dept. & can train other mechanics to make repairs
Score Mechanic skill before & after project 2.8 2.0 3.1 3.3 3.7 3.7 4.0 3.2 3.6 3.7 3.7 3.8 3.9 4.0 WILLY AJI ANDRE JENAL TATANG DENDI HARI SKILL MATRIX MECHANIC BEFORE AFTER 3.
Result on machine breakdown
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11_Skill Matrix_Multiskill Development & Training plan.pdf

  • 1. General Information Skill Matrix, Multi Skill Development & Training Plan
  • 2. General Information Goal Mampu membuat Skill Matrix & Rencana Training
  • 3. General Information Coach’s Background AJI WIJAYA KUSUMA, ST Enthusiast & professional on Lean, Improvement, people development and motivation. 16 years experience in Apparel Industry focus on practical lean implementation, costing & capacity management 471.wijayakusuma@gmail.com +62 815 7898 6913 Aji Wijaya Kusuma Lean Manufacturing Industrial Engineering Production Planning Apparel CMT Costing & CPM 90% 90% 80% 85% 85% Supplier Capacity Management https://www.youtube.com/user/471WijayaKusuma/featured https://www.facebook.com/Lets-LEAN-788239307962079
  • 5. General Information Layout lama ± 1-2 hari Mesin belum siap pakai Skill operator belum OK Kalo sore sisaan permakan masih ada
  • 6. General Information Training Within Industry Perang Dunia Ke-2
  • 7. General Information Q1 Q2 Q3 Q4 1 2 2 5 3 6 4 1 1 2 2 2 2 1 GREENTEX LEAN DEPT-- SKILL MATRIX & TRAINING PLAN SKILL NAME /PROCESS 1. Motion & Time Study 4. Presentation 3. 5S & Visual Performance 7. Problem Solving PDCA 2. Data Analyze & Visualization 5. Coaching 6. Inter Dept Relation REMARKS ACTUAL CAPABILITIES (75% PERFORMANCE) Manpower Needs Performance Needs (Work Manner) No. Reni 5 6 7 Riski Chairani NO SKILL KNOW THE THEORY CAN APPLY SOME OF THE THEORY HAVE APPLIED IN MOST OF ACTUAL PROBLEM CAN COACH OTHER WITH PROVEN RESULT Winarsih Putut Setiawan Remarks Job Needs (Poduction Change) RESULT OF TRAINING Beginning of Year Middle of Year End of Year SKILL LEVEL TARGET LEAN TEAM NAME
  • 8. General Information Remarks Job Needs (Poduction Change) End of Year Middle of Year RESULT OF TRAINING Beginning of Year 4 3 WATI 2 IKA 15 1 TINA ACTUAL 10 3 2 6 52 6 2 5 3 5 3 TARGET TOTAL OPERATOR 10 5 5 2 No. CAPABILITIES Manpower Needs Q1 Q2 Q3 Q3 Performance Needs (Work Manner) JOIN WB CROSS BOX JOIN HOOD SNAP/BARTACK PASANG PLACKET PASANG ZIPPER OVERDECK MAKE UP OVERLOCK SKILL MATRIX SEWING Name: Section/Group: Date: Process or Operation Name PENGUASAAN MESIN PENGUASAAN PROSES SPESIAL REMARKS SINGLE NEEDLE DOIBLE NEEDLE TARGET SKILL NAME
  • 9. General Information Creating a Planning Time-table MULTI-FUNCTION WORKER TRAINING TIMETABLE Name: REMARKS Section/Group: CAPABILITIES Date: NUMBER NAME 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. = 100% Performance = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks
  • 10. General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 5/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Forming Grinding Punching Seam Weld Edge Prep Tacking Spot Weld Flange Weld Paint KEY Increase orders 10% for the year Primer Step 1 Step 2
  • 11. General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 5/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Forming Grinding Punching Seam Weld Edge Prep Tacking Spot Weld Flange Weld Paint KEY Increase orders 10% for the year Primer Step 3 List Job Names
  • 12. General Information 1. Select Critical/Special Process/Machine Line Style SKETCH Proses critical Jenis mesin OUTPUT QUALITAS Namaoperator NIK Cross box Jarum 1 V V Saenur GIU0494 Obras pasangtangan Obras benang4 V Witri GIU2351 Obras variasi samping Obras benang4 V - Tutup kerah Jarum 1 V V Khomsiyatun GIU2088 Stick armhole Kamput V V Drsini GIU0971 Cross box Jarum 1 V V Mila GIU3636 Hemmingtangan Kamput V - Tutup kerah Jarum 1 V V Heni GIU0273 Cross box Jarum 1 V V Masriah GIU0277 Pasangkerah Jarum 1 V V Siti GIU1956 Stick slit Jarum 1 V V Biut GIU3783 Hemmingtangan Kamput V V Suhartiningsih GIU0758 Stick armhole /printing Kamput V Rohani GIU0290 Make up Make up V V Risna GIU0354 Obras kerah Obras benang4 V V Nuraini GIU0337 Stick zipper Jarum 1 V V iis GIU0210 Tutup kerah Jarum 1 V V Elis GIU4130 Pasangzipper Jarum 1 V V Mimin GIU0217 Pasangzipper Jarum 1 V V Uli GIU3204 Stick zipper Jarum 1 V V - Corongtape kerah Jarum 1 V V - Stick tape Jarum 1 V V - Stick zipper Jarum 1 V V Kiswati GIU2461 8 385FA 395FA 2 395FA 12 7 5 P31142 MSTR08390 DATA CRITICAL PROSES SEWING POLO 6 15 16
  • 13. General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 5/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Forming Grinding Punching Seam Weld Edge Prep Tacking Spot Weld Flange Weld Paint KEY Increase orders 10% for the year Primer Step 4 Assess Skill Levels
  • 14. General Information SKILL LEVEL PERSENTASE C 1%-25% Hanya dapat melakukan langkah-langkah dasar, dan masih belum lepas dari pengawasan B 26%-50% Dapat melakukan pekerjaan dengan aman, sesuai dengan kualitas yang diinginkan tapi belum mencapai target waktu yang ditetapkan. Masih membutuhkan banyak pengawasan S 76%-100% Tidak membutuhkan pengawasan dan dapat melatih karyawan lain untuk melakukan proses sewing yang ditargetkan A 51%-75% Dapat melakukan pekerjaan dengan aman, sesuai dengan kualitas yang diinginkan dan mencapai target waktu yang ditetapkan. Hanya butuh sedikit pengawasan SIMBOL KETERANGAN
  • 15. General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Step 5 Ideal number: the ideal number of people capable of doing the job at 75% performance or better
  • 16. General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Step 6 Step 6 Add Total Capabilities
  • 17. General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Performance needs: • Individual adherence to quality, rate and safety standards • Individual use of equipment and machines • Waste, rework, damage to equipment and injuries Step 8 Step 7 Manpower needs: • New employees • Promotions / transfers • Vacations • Temporary employees • Job rotations • Temporary assignments
  • 18. General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Production needs: • Work that piles up • Seasonal work • Bottlenecks • New Work • Production changes Step 9
  • 19. General Information MULTI-FUNCTION WORKER TRAINING SHEET Name: Ron Coleman REMARKS Section/Group: CAPABILITIES Date: 8/15/02 Jan Jun Dec NUMBER NAME 4 6 6 6 6 6 6 6 4 4 1. Ron Coleman (Supervisor) 10 10 2. Eddie Day (Team Leader) 3 4 3. Jeffe Goedde (Team Leader) 3 5 4. Bradley Alvey 2 4 5. Tina Brooks 6 7 6. Clark Campbell 3 4 7. Willie Coleman 1 4 8. Dennis Daniel 1 2 9. 10. 3 3 3 1 3 3 2 3 5 3 = 100% Performance 5 4 4 2 4 4 3 4 6 4 = 75% Performance = 50% Performance = In Training Process or Operation Name IDEAL NUMBER Manpower Needs Performance Needs (Work Manner) RESULT OF TRAINING Beginning of Year Middle of Year End of Year Job Needs (Production Change) Remarks Frame Department Chop Saw (2) HPP Glue and Dowel Frame Clamp (2) Prep/Inspect Special Busellato Giben Panel Saw Edgebander KEY Increase orders 10% for the year Parts Compare : • IDEAL CAPACITY to • RESULT OF TRAINING Examine : • Manpower Needs • Capabilities and • Job Needs to determine training needs. Step 10 Step 10 • Plan for and record anticipated training completion dates. • Write dates next to individual circles. Step 11
  • 20. General Information Copyright 2001 - 2008 Lean Associates, Inc.
  • 21. General Information Line Style SKETCH Proses critical Jenis mesin OUTPUT QUALITAS Nama operator NIK Cross box Jarum 1 V V Saenur GIU 0494 Obras pasang tangan Obras benang 4 V Witri GIU 2351 Obras variasi samping Obras benang 4 V - Tutup kerah Jarum 1 V V Khomsiyatun GIU 2088 Stick armhole Kamput V V Drsini GIU 0971 Cross box Jarum 1 V V Mila GIU 3636 Hemming tangan Kamput V - Tutup kerah Jarum 1 V V Heni GIU 0273 Cross box Jarum 1 V V Masriah GIU 0277 Pasang kerah Jarum 1 V V Siti GIU 1956 Stick slit Jarum 1 V V Biut GIU 3783 Hemming tangan Kamput V V Suhartiningsih GIU 0758 Stick armhole /printing Kamput V Rohani GIU 0290 Make up Make up V V Risna GIU 0354 Obras kerah Obras benang 4 V V Nuraini GIU 0337 Stick zipper Jarum 1 V V iis GIU 0210 Tutup kerah Jarum 1 V V Elis GIU 4130 Pasang zipper Jarum 1 V V Mimin GIU 0217 Pasang zipper Jarum 1 V V Uli GIU 3204 Stick zipper Jarum 1 V V - Corong tape kerah Jarum 1 V V - Stick tape Jarum 1 V V - Stick zipper Jarum 1 V V Kiswati GIU 2461 8 385 FA 395 FA 2 395 FA 12 7 5 P31142 MSTR08390 DATA CRITICAL PROSES SEWING POLO 6 15 16 2. Select Best Operator To Do TOT (Training Of Trainer)
  • 22. General Information 3. Train the best operator with Lean Method (JI) www.themegallery.com Company Logo
  • 25. Perbaikan Terus-Menerus ❖ Update Weekly/Monthly untuk Skill Level % ❖ Merencanakan lebih awal jika ada resign dan rotasi ❖ Memperbaiki ISQ/RFT Factory Category Level - HR Data S A B C 5% 25% 40% 30% IY 01 12.4% 29.7% 34.5% 18.4% IY 02 6.6% 17.0% 36.1% 26.1% IY 03 7.9% 26.1% 35.7% 26.3% IY 04 9.1% 27.5% 38.2% 21.4% IY 05 9.1% 29.8% 28.5% 24.0% IY 07 7.5% 31.4% 29.7% 19.8% IY 08 7.3% 21.4% 36.8% 22.0% IY 09 4.8% 15.1% 37.4% 29.2% IY 10 6.0% 21.8% 40.3% 23.1% IY 12 4.3% 21.1% 35.5% 25.6% IY 13 6.9% 20.9% 33.9% 20.0% IY 14 11.1% 36.1% 21.7% 23.4% OUTSOLE 0.0% 34.8% 35.9% 4.0% TOTAL 6.5% 25.9% 34.4% 20.3%
  • 28. Visual Control Mechanic Development Skill No NAME Machine Problem Focus Analyze Std Total Time Setting + repair (Minute ) Education Skill Update: 19 Feb Update: 26 Mar Update: 16 Apr Update: 11 Mei Update: 3 Jun Update: 15 Jun Update: 07 Jul Update: 10 August Update: 19 Feb Update: 26 Mar Update: 16 Apr Update: 11 Mei Update: 3 Jun Update: 15 Jun Update: 07 Jul Update: 10 August 1 Dendi Overdeck ( 3 Neddle, Cutt ) Jumping Stitch 3,7 3,8 3,9 3,6 3,7 3,9 20 2 Tatang 3,7 3,7 3,8 3,8 3,4 3,6 3,6 3,7 3 Aji 2,0 2,6 3,6 3,0 2,9 3,3 4 Jenal 3,3 3,7 3,7 3,3 3,4 3,7 5 Andre 3,1 3,3 3,7 3,3 3,3 3,4 6 Hari 4,0 4,0 3,9 3,9 7 Willy 2,8 3,1 3,2 2,7 2,7 3,0 NOTE SCORE REMARKS 0 Can not repairing machine 1 Can carry out basic repairing machine 2 Can carry out basic repairing machine + requires intermediate supervision 3 Can carry out basic repairing machine + requires advance supervision 4 Can carry out basic repairing machine , propose improvement ideas, be able to work with other Dept. & can train other mechanics to make repairs
  • 29. Score Mechanic skill before & after project 2.8 2.0 3.1 3.3 3.7 3.7 4.0 3.2 3.6 3.7 3.7 3.8 3.9 4.0 WILLY AJI ANDRE JENAL TATANG DENDI HARI SKILL MATRIX MECHANIC BEFORE AFTER 3.
  • 30. Result on machine breakdown