Basic Quality
Training Material
Rio Yudha Prawira
QA Asst. Manager
Quality Assurance
(Astemo) IDBB
September 23rd, 2021
CONFIDENTIAL
Contents
1. Quality Awareness
2. Basic Action & Rules
3. Pentingnya Mutu
3. In-process Defect (Customer Line Claim & Internal Reject).
4. Outgoing, Process & Incoming Quality Control.
5. SQM Activity.
6. New Development/Engineering Change Control.
7. Others.
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
2
1. Quality Awareness
Kualitas (Mutu) adalah:
“Setiap karakteristik (fitur) dari produk yang sesuai dengan keinginan
pelanggan atau sesuai dengan tujuan penggunaan dari produk tersebut”
Produk yang berkualitas adalah produk yang:
1. Sesuai dengan keinginan pelanggan
2. Dapat digunakan sesuai dengan fungsinya
3. Sesuai dengan spesifikasi produk yang telah ditetapkan
Salah satu contoh spesifikasi produk adalah Drawing
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
3
1. Quality Awareness
Kebijakan Mutu Hitachi Astemo
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
4
1. Quality Awareness
Prinsip “Quality First” Hitachi
 Pahami sudut pandang pelanggan.
Pelanggan adalah yang utama.
 Kualitas adalah prioritas utama.
Jangan mengabaikan kualitas demi pengiriman ataupun biaya.
 Penjaminan melalui pengujian dan verifikasi yang empiris
Perhitungan, trial produksi dan pengujian sangatlah penting.
Buat keputusan berdasarkan prinsip 5-Gen.
Prinsip 5-Gen: Genba (Lokasi), Genbutsu (Objek Aktual), Genjitsu
(Kondisi Aktual), Genri (Prinsip) dan Gensoku (Aturan)
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
5
1. Quality Awareness
Panduan dalam bertindak
Tempatkan diri Anda sebagai pelanggan.
⇒ Bertindaklah seolah-olah Andalah pelanggannya.
Jangan menutupi kesalahan.
⇒ Ungkapkan yang sebenarnya.
Jangan berkompromi demi pengiriman dan penghematan biaya.
⇒ Kuaitas harus jadi yang utama.
Mulailah dengan kecurigaan, jangan dengan kepercayaan.
⇒ Kebenaran terkadang tersembunyi.
Berinisiatiflah untuk introspeksi diri.
⇒ Bebas, bertanggung jawab dan saling membantu.
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
6
1. Quality Awareness
Mengapa mutu adalah prioritas utama?
Penambahan Biaya
- Kompensasi untuk pelanggan
- Biaya pengiriman, biaya rework, scrap, dan lain-lain
Kualitas
Buruk
Kehilangan Kepercayaan Pelanggan
- Reputasi yang baik akan dibicarakan 5 orang,
reputasi yang buruk akan disebarkan ke 10
orang
Ketidaknyamanan/Ketidakamanan bagi Pelanggan
- Kualitas yang buruk dapat menyebabkan
ketidaknyamanan bahkan mengancam keselamatan
pelanggan
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
7
2. Basic Actions & Rules
•
•
•
•
•
HORENSO: Lapor, Komunikasi dan Konsultasi
Kontrol 5S control dan 3T
Standard Operasi
Pengendalian Produk Tidak Sesuai
Penanganan Abnormality
CONFIDENTIAL
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8
2. Basic Actions & Rules
(HORENSO: Lapor, Komunikasi dan Konsultasi)
(HORENSO) adalah sederet Tindakan “pelaporan (Hokoku)”, “komunikasi
(Renraku)” dan “konsultasi (Sodan)” yang sangat penting dalam bekerja.
<Pelaporan>
Bawahan harus melaporkan setiap progress atau hasil kerja kepada atasan
sesuai dengan yang diinstruksikan.
<Komunikasi>
Setiap informasi harus disampaikan kepada atasan dan bawahan. Informasi
yang disampaikan tidak boleh berdasarkan opini pribadi atau perkiraan
pribadi.
<Konsultasi>
Lakukan konsultasi dengan atasan, senior, dan rekan kerja untuk
mendapatkan saran atau referensi dalam mengambil keputusan.
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
9
2. Basic Actions & Rules
Jangan Lakukan
やってはいけないこと
(Manajemen 5S)
1S: Seiri (Ringkas)
1S: Pisahkan barang yang dibutuhkan
dengan yang tidak dibutuhkan.
Singkirkan barang yang tidak
dibutuhkan.
* Jangan membawa apapun yang
tidak dibutuhkan.
Lakukan
正しい作業
Aktivitas Ringkas dapat
dilakukan untuk area kerja,
aktivitas dan informasi.
Buang
廃却箱
Apa要るものは？
yang dibutuhkan?
Dibutuhkan
要るもの
Tidak
Dibutuhkan
要らない物
CONFIDENTIAL
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10
2. Basic Actions & Rules
Jangan Lakukan
やってはいけないこと
(Manajemen 5S)
Spanner
スパナ
2S: Seiton (Rapi)
Screw
driver
ドライバー
Pipe
wrench
パイプレンチ
ハンマー
Hammer
2S: Susun barang yang diperlukan
dan beri label agar orang lain
dapat mengetahui dan melihat
lokasi penyimpanannya.
Pipe wrench
パイプレンチ
プライヤー
Pliers
Hammer
ハンマー
Pliers
プライヤー
Screw
driver
ドライバー
パイプレンチ
Pipe wrench
Hammer
ハンマー
Screw
driver
ドライバー
* Jangan meninggalkan barang
secara sembarangan setelah
digunakan
Lakukan
正しい作業
Spanner
スパナ
Spanner
スパナ
Pliers
プライヤー
Pemberian label sangat penting untuk
aktivitas “Seiton” karena orang sering
lupa atau tidak tahu lokasi
penyimpanannya.
Diperlukan
要るもの
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
11
2. Basic Actions & Rules
(Manajemen 5S)
Jangan Lakukan
やってはいけないこと
3S: Seisou
(Resik)
3S: Bersihkan dan jaga kebersihan
lingkungan
* Jangan biarkan barang atau
lingkungan dalam kondisi kotor
Lakukan
正しい作業
Barang dan lingkungan kerja
harus dalam kondisi bersih.
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
12
2. Basic Actions & Rules
Jangan Lakukan
やってはいけないこと
(Manajemen 5S)
Spanner
スパナ
ドライバー
Pipe
wrench
パイプレンチ
4S: Seiketsu (Rawat)
Hammer
ハンマー
４S: Jaga kebersihan lingkungan
dengan melakukan Ringkas, Rapi
dan Resik.
プライヤー
* Jangan mengabaikan 3S
Lakukan
正しい作業
Spanner
スパナ
Screw
driver
ドライバー
3S harus dilakukan secara terus
menerus untuk menjaga
lingkungan yang bersih.
Pipe wrench
パイプレンチ
Hammer
ハンマー
Pliers
プライヤー
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
13
2. Basic Actions & Rules
Jangan Lakukan
やってはいけないこと
(Manajemen 5S)
5S: Shitsuke (Rajin)
5S: Ikutilah aturan
Lakukan
正しい作業
スパナ
Spanner
* Jangan mengabaikan aturan
ドライバー
Screw
driver
Selalu ikuti aturan kerja dan
jagalah kedisiplinan.
Pipe
wrench
パイプレンチ
ハンマー
Hammer
Pliers
プライヤー
Cleaning
Check Sheet for **** (MM/YYYY)
○○年○月度・清掃活動チェ
ックシート
Checked
Facility
by
設備
担当
12345
1
Ａ
○ ○
2
Ｂ
○ ○
3
C
○ ○
Note
備考
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
14
2. Basic Actions & Rules
Jangan Lakukan
やってはいけないこと
(Manajemen 3T)
Teii: Dimana
(Tentukan lokasi)
• Taruh barang di tempat yang
telah ditentukan.
• Jangan meninggalkan barang dalam
kondisi berantakan
Lakukan
正しい作業
The
first tray of Cabinet A
Ａの１段目
CONFIDENTIAL
Jika lokasi penyimpanan tidak
ditentukan, orang akan menyimpan
barang secara sembarangan.
Sangat penting untuk menentukan
lokasi penyimpanan barang.
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
15
2. Basic Actions & Rules
Jangan Lakukan
やってはいけないこと
(Manajemen 3T)
Teihin: Apa
(Tentukan barang apa
yang harus disimpan)
• Tentukan barang yang harus
disimpan
Lakukan
正しい作業
• Jangan mengganti barang yang
disimpan tanpa izin.
Orang akan bingung jika ada
barang yang diletakkan tidak
pada tempatnya.
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
16
2. Basic Actions & Rules
Jangan Lakukan
やってはいけないこと
(Manajemen 3T)
Teiryo: Seberapa banyak
(Tentukan jumlah yang
seharusnya)
• Tentukan jumlah kebutuhan
untuk setiap barang
• Jangan menyimpan barang lebih
dari yang dibutuhkan.
Lakukan
正しい作業
Penting untuk menetapkan dan menjaga
jumlah yang cukup untuk setiap barang.
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
17
2. Basic Actions & Rules
(Standard operasi)
Standard operaasi adalah dokumen yang menentukan “cycle time”,
“urutan kerja” dan “standard jumlah pekerjaan dalam suatu proses” yang
mengkombinasikan manusia, barang, dan peralatan untuk mendapatkan
hasil yang diinginkan.
Tiga elemen
1. Cycle time
Menentukan waktu (**m **s) untuk menghasilkan satu piece (lot) produk.
2. Urutan kerja
Urutan atau tahapan pekerjaan yang paling efisien.
3. Standard jumlah pekerjaan dalam suatu proses
Standard minimum jumlah pekerjaan yang harus dilakukan dalam satu
proses.
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
18
2. Basic Actions & Rules
mes/día
Cont revisión
Elaboró
Aprobó
Jangan Lakukan
やってはいけないこと
(Standard operasi)
なぜ・・・
Mengapa? Untuk
異品・欠品・
mengcegah
kesalahan
加工ミス防止
proses
Jangan menghentikan
pekerjaan di pertengahan
cycle
の為！
Hey.
オーイ
Ya?
ハーイ
JK-203
JK-203
JK-203
* Selesaikan satu cycle pekerjaan.
* Jangan tinggalkan area kerja
di tengah-tengah proses.
Lakukan
正しい作業
One cycle
１サイクル
Ya?
何ですか？
Hey.
オーイ
Tinggalkan area
1 kerja
サイクル終了後に
setelah
離れる。
selesai
satu cycle
Aku
selesaikan
１サイクル
dulu
pekerjaan
終わるまで
ini
JK-203
JK-203
JK-203
CONFIDENTIAL
Standard operation sheets specify the
scope of work in terms of worker’s
motion.
1. Takt time for repeated work
2. Standard number of works in
process
3. Quality check items
4. Safety cautions
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
19
2. Customer Notification & External Defect (Warranty Claim).
2.1. Customer – Quality Delivery Assessment.
Based on AHM evaluation:
1. EPS (Evaluasi Performa Supplier – AHM Procurement)
2. GQI (Global Quality Index – HONDA Global Quality)
Month
Apr
May
EPS
EXCEL
GQI
EXCEL
Jun
Jul
Aug
Sep
Level : Excellent, Good, Fair, Poor
Level : Excellent, Good, Fair, Poor
Oct
Nov
Dec
Jan
Feb
Mar
2.2. External Defect – Warranty Claim Data (End User Claim).
1HFY21
Budget
Apr
Sale
Amount
36.332
51.053
51.053
QTY
-
0
0
Paid
Amount
2
0
0
Ratio
0,005
0,00%
0,00%
May
Jun
CONFIDENTIAL
Jul
Aug
Sep
1HFY21
Actual
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
20
3. In-process Defect (Customer Line Claim)
Model
Apr-21
May-21
K59J
45.600
K0JA
4.800
K60R
50.500
Jun-21
Jul-21
Aug-21
Sep-21
AHM Pt. 3
Delivery
AHM Pt. 4
Claim
K59J
0
K0JA
0
K60R
0
PPM
0
PPM Target
10
PICA/CAR
Date
Model
Qty
Symptom
Status
Issue Date
CONFIDENTIAL
PICA/CAR No.
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
21
3. In-process Defect (Internal Reject)
3.1. Pareto of Internal Reject
12 180
97%
11 243
87%
10 306
9 370
78%
8 433
68%
7 496
58%
6 559
Period: April 1st – 30th , 2021
Issued Date: May 20th , 2021
Issued by: Rio Yudha Prawira
5 622
4 685
3 748
2 811
49%
39%
29%
19%
1 874
10%
937
0%
0
Seal Piston
Cylinder Seal Wiper Cylinder
Finish
Finish (MC)
(CALIPER)
Bleeder
Lever
Boot
Stop Ring
MASTER Bolt Torx
CYLINDER
ASSY
(KOIKE)
Bolt
O-ring Level
Washer
Insulator
Level
Indicator
Others
3.2. Top 3 of Scrapped Parts
No.
Part Name
1
Seal Piston
2
Cylinder Finish (CALIPER)
3
Seal Wiper
Qty
Amount
1.391
1.681.719
24
1.306.272
1.392
861.648
CONFIDENTIAL
Reason for Scrap
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22
4. Outgoing, Process & Incoming Quality Control.
4.1. Outgoing Inspection.
Apr-21
Production Lot
1229
Accepted Lot
1227
Accepted Lot Percentage
No.
1
Problem
May-21
Jun-21
Jul-21
Aug-21
Sep-21
99.8%
Picture
Current Activity
Countermeasure
Plan
Due Date
Peel off on Body M/C
and Body Caliper
CONFIDENTIAL
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23
4. Outgoing, Process & Incoming Quality Control.
4.2. Process QC Data (% Rejection).
Model
Process
MASTER
K59J
CALIPER
SYSTEM
MASTER
K0JA
CALIPER
SYSTEM
MASTER
K2FF
CALIPER
SYSTEM
Line
Apr-21
May-21
Jun-21
Jul-21
Aug-21
Sep-21
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
CONFIDENTIAL
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24
4. Outgoing, Process & Incoming Quality Control.
Model
Process
Station
Problem
MASTER
K59J
CALIPER
SYSTEM
MASTER
K0JA
CALIPER
SYSTEM
MASTER
K2FF
CALIPER
SYSTEM
CONFIDENTIAL
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25
4. Outgoing, Process & Incoming Quality Control.
4.3. Incoming Inspection.
Apr-21
May-21
Jun-21
Jul-21
Aug-21
Sep-21
Delivered Qty
Rejected Qty
PPM
PPM Target
No.
Occurred
Date
Supplier Name
Part
CONFIDENTIAL
Problem
Temporary Action
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26
4. Outgoing, Process & Incoming Quality Control.
4.4. Problem and Countermeasure Follow Up
CONFIDENTIAL
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27
4. Outgoing, Process & Incoming Quality
Control.
4.5. Returned Material Approval (RMA).
RMA ( Return Material Approval ) FY20
Payment
Status
FY 2019
April-20
May-20
Jun-20
Jul-20
Aug-20
Sep-20
Oct-20
Nov-20
Des-20
Jan-21
TOTAL
Total RMA
IDR
85,624,728
IDR
-
IDR
-
IDR
-
IDR
386,295
IDR
29,395,413
IDR
14,549,455
IDR
4,662,493
IDR
33,232,022
IDR
584,622
IDR
781,990
IDR
169,217,018
Paid
IDR
84,329,912
IDR
-
IDR
-
IDR
-
IDR
386,295
IDR
29,395,413
IDR
14,549,455
IDR
4,662,493
IDR
6,577,907
IDR
-
IDR
-
IDR
139,901,475
Out standing
IDR
1,294,816
IDR
-
IDR
-
IDR
-
IDR
-
IDR
-
IDR
-
IDR
-
IDR
26,654,115
IDR
584,622
IDR
781,990
IDR
29,315,543
Remark
RMA ( RETURN MATERIAL APPROVAL ) FY20
IDR 139 901 475
IDR 160 000 000
IDR 169 217 018
IDR 85 624 728
IDR 140 000 000
IDR 84 329 912
IDR 120 000 000
IDR 100 000 000
IDR 26 654 115
IDR 29 395 413
IDR 80 000 000
IDR 14 549 455
IDR 4 662 493
IDR 29 395 413 IDR 14 549 455
IDR 1 294 816
IDR 60 000 000
IDR 781 990
IDR 386 295
IDR 40 000 000
IDR 6 577 907
IDR 4 662 493
IDR 386 295
IDR 20 000 000
IDR IDR
- IDR
- -
IDR IDR
- IDR
- -
April-20
May-20
IDR -IDR -
IDR -
IDR 29 315 543
IDR 33 232 022
IDR 584 622
IDR IDR -
IDR 781 990
IDR 584 622
IDR -
IDR -
IDR -
IDR -
Des-20
Jan-21
IDR FY 2019
Jun-20
Jul-20
Total RMA
Aug-20
Paid
CONFIDENTIAL
Sep-20
Oct-20
Nov-20
TOTAL
Out standing
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
28
4. Outgoing, Process & Incoming Quality
Control.
4.6. Returned Material Approval (RMA).
RMA List FY20
Action
Month
Sep-19
Supplier
Hitachi Asia
GW
Part Name
Master Cylinder
Finish
Problem
QA SUPPLIER APPROVAL
QI
Dimension 27 mm
IQC-QI-09& 34 mm Out of
19-002
Spec.
Qty
Unit price
(IDR)
Scrap , Man Power ,
Tool , Material
Detail action
Man Power
Sorting Cost
608 Hour
40463/Hour
Man Power
Re use Cost
16 Hour
40463/Hour
IDR
647,408.00
Tool
Jig Inspection
20 Pcs
50000/Pcs
IDR
1,000,000.00
Tool
Dies Special Bolt
Lever
1 Units
Material
Material
Issue date
Bolt Lever After used 1912 Pcs
Nut Flange After
used
1912 Pcs
Hitachi Asia
GW
Master Cylinder
Finish
Painting
Contamination
Hitachi Asia
GW
Master Cylinder
Finish
Thread NG
Hitachi Asia
GW
Master Cylinder
Finish
Dented Grade A
Hitachi Asia
GW
Caliper Cylinder
Finish
Dented Grade A
Feb-20
IQC-QI-0220-003
GW Check
Actual Part
( Refer To
Inventory
List
Holding
Part GW
FEBRUARY2020 )
PIC /
Supplier
DN/HIAM
23-Oct-20 23-Dec-20
S/20/014
CLOSE
GW
17-Sep-20
6-Oct-20
DN/HIAM
23-Oct-20 23-Dec-20
S/20/014
CLOSE
GW
17-Sep-20
6-Oct-20
DN/HIAM
23-Oct-20 23-Dec-20
S/20/014
CLOSE
GW
35000000
IDR
17-Sep-20
35,000,000.00
6-Oct-20
DN/HIAM
S/20/014- 23-Oct-20 23-Dec-20
1
CLOSE
GW
2280/Pcs
IDR
4,359,360.00
17-Sep-20
6-Oct-20
DN/HIAM
23-Oct-20 23-Dec-20
S/20/014
CLOSE
GW
163/Pcs
IDR
311,656.00
17-Sep-20
6-Oct-20
DN/HIAM
23-Oct-20 23-Dec-20
S/20/014
CLOSE
GW
IDR
17-Sep-20
65,919,928.00
6-Oct-20
CLOSE
GW
1-Oct-20
CLOSE
GW
DN/HIAM
29-Apr-20 30-Sep-20
S/20/006
CLOSE
GW
1-Oct-20
CLOSE
GW
IDR
27-Mar-20
11,005,936.00
DN/HIAM
31-Mar-20 S/20/006- 14-Jul-20
1 Rev.1
Man Power
Sorting Cost
272 Hour
40463/Hour
Material
Scrap
3 Pcs
106.39 THB /
Pcs
฿
319.17
27-Mar-20
31-Mar-20
Man Power
Repair Cost
48 Hour
40463/Hour
IDR
1,942,224.00
27-Mar-20
DN/HIAM
31-Mar-20 S/20/006- 14-Jul-20
1 Rev.1
Material
Scrap
14 Pcs
106.39 THB /
Pcs
฿
1,489.46
27-Mar-20
31-Mar-20
DN/HIAM
29-Apr-20 30-Sep-20
S/20/006
CLOSE
GW
Material
Scrap
57 Pcs
106.39 THB /
Pcs
฿
6,064.23
27-Mar-20
31-Mar-20
DN/HIAM
29-Apr-20 30-Sep-20
S/20/006
CLOSE
GW
Material
Scrap
14 Pcs
118,13 THB /
Pcs
฿
1,653.82
27-Mar-20
31-Mar-20
DN/HIAM
29-Apr-20 30-Sep-20
S/20/006
CLOSE
GW
Master Cylinder Diameter 6 Out of IQC-QI-12Finish
Spec
19-002_R1
Hitachi Asia
GW
IDR
17-Sep-20
24,601,504.00
Approval date Invoice NO Issue Date
Status
Payment
Date
6-Oct-20
Total
Dec-19
ISSUE DEBIT NOTE
Amount
(IDR)
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
29
4. Outgoing, Process & Incoming Quality
Control.
4.6. Returned Material Approval (RMA).
Action
Month
Mar-20
Jul-20
Supplier
Part Name
Problem
QA SUPPLIER APPROVAL
QI
IQC-QIL-0320-001
Nichirin
Hosebrake
Hose end Mixing
Hitachi Asia
GW
Master Cylinder
Finish
Diameter 6 Out of
IQC-QI-03Spec. ( Lot T23 &
20-002
T2Q )
Nichirin
Hosebrake
Hose end Mixing
IQC-QIL-0720-006
Unit price
(IDR)
Qty
Holder Cable
Painting Fade
Holder Cable Luntur IQC-QIL-08( Finish Good )
20-005
15-Sep-20
CLOSE
NICHRIN
DN/HIAM
10-Sep-20
S/20/010
30-Sep-20
CLOSE
BMT
9-Sep-20
DN/HIAM
10-Sep-20
S/20/010
30-Sep-20
CLOSE
BMT
3-Sep-20
9-Sep-20
DN/HIAM
10-Sep-20
S/20/010
30-Sep-20
CLOSE
BMT
IDR
7,197,542.00
3-Sep-20
9-Sep-20
DN/HIAM
10-Sep-20
S/20/010
30-Sep-20
CLOSE
BMT
IDR
187,264.00
3-Sep-20
9-Sep-20
DN/HIAM
10-Sep-20
S/20/010
30-Sep-20
CLOSE
BMT
IDR
7,992,806.00
3-Sep-20
9-Sep-20
CLOSE
BMT
IDR
2,424,543.00
1-Oct-20
2-Oct-20
DN/HIAM
23-Oct-20
S/20/012
9-Nov-20
CLOSE
WATANA
BE
IDR
1,157,004.00
11-Mar-20
12-Mar-20
DN/HIAM
12-Jun-20
S/20/008
Man Power
Sorting base on Lot
Machining
32 Hour
40463/Hour
IDR
1,294,816.00
1-Jul-20
16-Sep-20
DN/HIAM
18-Sep-20
S/20/011
Material
Scrap
1 Pcs
386295/Pcs
IDR
386,295.00
22-Jul-20
7-Aug-20
DN/HIAM
10-Aug-20
S/20/009
Dismatle Cost
95 Pcs
1000/Pcs
IDR
95,000.00
3-Sep-20
9-Sep-20
Ressy Cost
95 Pcs
1000/Pcs
IDR
95,000.00
3-Sep-20
Dismatle Cost
418 Pcs
1000/Pcs
IDR
418,000.00
Assy Procces
418 Pcs
17219/Pcs
Bolt torx
418 Pcs
448/Pcs
Sorting Cost
59.92 Hour 40463/Hour
Material
NG Part + From AQL
Check
Material
Finish Good
Approval date Invoice NO
Issue Date Payment Date
15-Jul-20
DN/HIAMS/20/010
9496 Pcs
634/Pcs
IDR
6,020,464.00
1-Oct-20
2-Oct-20
DN/HIAM
23-Oct-20
S/20/012
9-Nov-20
CLOSE
WATANA
BE
5600 Pcs
727/Pcs
IDR
4,071,200.00
1-Oct-20
2-Oct-20
DN/HIAM
23-Oct-20
S/20/012
9-Nov-20
CLOSE
WATANA
BE
6000 Pcs
686/Pcs
IDR
4,116,000.00
1-Oct-20
2-Oct-20
DN/HIAM
23-Oct-20
S/20/012
9-Nov-20
CLOSE
WATANA
BE
3600 Pcs
614/Pcs
IDR
2,210,400.00
1-Oct-20
2-Oct-20
DN/HIAM
23-Oct-20
S/20/012
9-Nov-20
CLOSE
WATANA
BE
4000 Pcs
640/Pcs
IDR
2,560,000.00
1-Oct-20
2-Oct-20
DN/HIAM
23-Oct-20
S/20/012
9-Nov-20
CLOSE
WATANA
BE
IDR
21,402,607.00
1-Oct-20
2-Oct-20
DN/HIAMS/20/012
9-Nov-20
CLOSE
WATANA
BE
Total
Holder Cable
GW
385668/Pcs
Aug-20
BMT
CLOSE
3 Pcs
IQC-QIL-0820-05
IQC-QIL-0820-003
NICHRIN
Scrap
Man power
O Ring Broken
CLOSE
Material
Issue date
Total
O Ring Level
PIC /
Supplier
Detail action
Material
Watanabe
Rubber
Status
Scrap , Man Power , Tool
, Material
Man Power
BMT
ISSUE DEBIT NOTE
Amount
(IDR)
Pending
: BMTIDRLooking another methode for rework discuss
307256/Pcs
116,450,024.00
with PT Nippon Paint
379 Pcs
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
BMT
30
4. Outgoing, Process & Incoming Quality
Control.
4.6. Returned Material Approval (RMA).
Action
Month
Supplier
Part Name
Problem
Burr Inside ID
Hitachi Master
Asia
Cylinder
GW
Finish
QA SUPPLIER APPROVAL
QI
IQC-QI-0820-001 R1
& IQC-QI09-20-002
R1
Qty
Issue date
Man Power
Sorting Cost
278
IDR
40463/Hour
1-Oct-20
Hour
11,248,714.00
Tool
Sub Material :
Flashlight
4 Pcs
20000/Pcs
IDR
80,000.00
1-Oct-20
Tool
Sub Material :
Batery A3
42 Pcs
3750/Pcs
IDR
157,500.00
1-Oct-20
Man Power
Repair Cost
12
40463/Hour
Hour
IDR
485,556.00
26-Oct-20
Tool
Special Jig For
Repair
3 Pcs 200000/Pcs
IDR
600,000.00
26-Oct-20
Material
Master Cyl Finish :
Casting Problem 25 Pcs 49914/Pcs
(1D )
Oct-20
BMT
Cap Reservoir
Peel off
IQC-QIL-1020-003
IDR
26-Oct-20
1,247,850.00
IDR
26-Oct-20
13,819,620.00
Approval
date
GW
17-Nov29-Jan-21 CLOSE
20
GW
17-Nov29-Jan-21 CLOSE
20
GW
17-Nov29-Jan-21 CLOSE
20
GW
17-Nov29-Jan-21 CLOSE
20
GW
17-Nov29-Jan-21 CLOSE
20
GW
5-Nov-20 DN/HIAMS/20/017 29-Jan-21 CLOSE
GW
5-Oct
5-Oct
Sorting Cost
16
Hour
40463/Hour
IDR
647,408.00
26-Oct
28-Oct
Screw Flat
1764
Pcs
98/Pcs
IDR
172,872.00
26-Oct
28-Oct
26-Oct
28-Oct
Man Power
Material
Total
CONFIDENTIAL
IDR
820,280.00
PIC /
Supplier
17-Nov29-Jan-21 CLOSE
20
IDR
729,835.00
Caliper Assy
Invoice
Payment
Issue Date
NO
Date
DN/HIA
6-Oct-20 MS/20/0
17
DN/HIA
6-Oct-20 MS/20/0
17
DN/HIA
6-Oct-20 MS/20/0
17
DN/HIA
5-Nov-20 MS/20/0
17
DN/HIA
5-Nov-20 MS/20/0
17
DN/HIA
5-Nov-20 MS/20/0
17
5 Pcs 145967/Pcs
Material
ISSUE DEBIT NOTE
Status
Detail action
Total
Grakind
IQC-QILUnion Bolt Patah ( Broken )
o
09-20-003
Amount
(IDR)
Scrap , Man Power ,
Tool , Material
Sep-20
Casting on Grade IQC-QI-09A Area
20-001 R1
Unit price
(IDR)
DN/HIA
23-OctGrakind
MS/20/0
4-Nov-20 CLOSE
20
o
13
DN/HIA
30-OctMS/20/0
27-Nov-20 CLOSE
20
15
DN/HIA
30-OctMS/20/0
27-Nov-20 CLOSE
20
15
DN/HIAMS/20/015 27-Nov-20 CLOSE
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
BMT
BMT
BMT
31
4. Outgoing, Process & Incoming Quality
Control.
4.6. Returned Material Approval (RMA).
Action
Month
Supplier
Part Name
Problem
QA SUPPLIER APPROVAL
QI
Qty
Scrap , Man
Power , Tool ,
Material
Unit price
(IDR)
ISSUE DEBIT NOTE
Amount
(IDR)
Detail action
Issue date
Approval date Invoice NO Issue Date
Status
PIC /
Supplier
Payment
Date
Sorting Cost
52.7
Hour
40463/Hour
IDR
2,132,400.10
28-Oct
30-Oct
DN/HIAM
4-Nov-20 11-Jan-21
S/20/016
CLOSE
DPM
Repair Cost
9.4
Hour
40463/Hour
IDR
380,352.20
28-Oct
30-Oct
DN/HIAM
4-Nov-20 11-Jan-21
S/20/016
CLOSE
DPM
10/28/2020
10/30/2020
CLOSE
DPM
Man Power
DPM
Screw Flat
Not Full Plating ( IQC-QIL-10Plating tidak rata )
20-004
'Oct-20
IDR
2,512,752.30
Total
Washer
11-Jan-21
Man Power
Sorting Cost
4 Hour
40463/Hour
IDR
161,852.00
20-Nov
24-Nov
DN/HIAM 25-Nov22-Dec-20 CLOSE
S/20/018
20
RKI
Material
Finish Good
3 Pcs
389203/Set
IDR
1,167,609.00
20-Nov
24-Nov
DN/HIAM 25-Nov22-Dec-20 CLOSE
S/20/018
20
RKI
Material
Finish Good
1 Pcs
389203/Set
IDR
389,203.00
20-Nov
24-Nov
DN/HIAM 25-Nov22-Dec-20 CLOSE
S/20/018
20
RKI
11/20/2020
11/24/2020
12/22/2020 CLOSE
RKI
20-Nov
24-Nov
DN/HIAM 25-Nov22-Dec-20 CLOSE
S/20/019
20
RKI
11/20/2020
11/24/2020
IQC-QIL-1020-006
RKI
DN/HIAMS/20/016
Dented & Damage
IQC-QIL-1120-004
IDR
1,718,664.00
Total
DN/HIAMS/20/018
Nov-20
IQC-QIL-1120-001
RKI
Level Indicator
Material
Finish Good
8 Pcs
389203/Set
IDR
3,113,624.00
Sink Mark
Total
CONFIDENTIAL
IDR
3,113,624.00
DN/HIAMS/20/019
12/22/2020 CLOSE
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
RKI
32
4. Outgoing, Process & Incoming Quality
Control.
4.6. Returned Material Approval (RMA).
Action
Month
Supplier
Part Name
Problem
QI
Scrap , Man
Power , Tool ,
Material
Man Power
Man Power
Grakindo
Bolt
Damage/Dented
IQC-QIL-1120-006
Material
Material
QA SUPPLIER APPROVAL
Qty
Unit price
(IDR)
Detail action
Nov-20
BMT
Holder Mirror
No Thread
IQC-QIL11-20-005
Master Cylinder
Finish
Dimension 53 mm IQC-QI-11Out of Spec
20-002
Approval
date
Invoice
Payment
Issue Date
NO
Date
DN/HIA
30-Nov-20 15-Dec-20 MS/20/0
21
DN/HIA
IDR
Controller ( Leader ) 8 Hour 98456/Hour
30-Nov-20 15-Dec-20 MS/20/0
787,648.00
21
DN/HIA
IDR
F/G K59
1 Set 315212/Set
30-Nov-20 15-Dec-20 MS/20/0
315,212.00
21
DN/HIA
IDR
F/G K2FF
3 Set 361428/Set
30-Nov-20 15-Dec-20 MS/20/0
1,084,284.00
21
Sorting Cost
17
IDR
49228/ Hour
Hour
836,876.00
Holder Mirror (
Warranty Claim )
PIC /
Supplier
23-DecGrakind
20-Jan-21 CLOSE
20
o
23-DecGrakind
20-Jan-21 CLOSE
20
o
23-DecGrakind
20-Jan-21 CLOSE
20
o
23-DecGrakind
20-Jan-21 CLOSE
20
o
IDR
11/30/2020 12/15/2020 DN/HIAMS/20/021 20-Jan-21 CLOSE Grakindo
3,024,020.00
1 Pcs 51060/PCs
IDR
51,060.00
IDR
51,060.00
Total
Hitachi Asia
GW
ISSUE DEBIT NOTE
Status
Issue date
Total
Material
Amount
(IDR)
DN/HIA
18-Dec17-Dec-20 17-Dec-20 MS/20/0
29-Jan-21 CLOSE
20
20
BMT
DN/HIAM 12/18/202
1/29/2021 CLOSE
S/20/020
0
BMT
12/17/2020 12/17/2020
Man Power
Sorting Cost ( By
Visual )
361.8
IDR
49228/Hour
21-Dec-20
Hour
17,810,690.40
22-Jan-21
DN/HIAM
29-Jan-21
S/21/025
OPEN
GW
Man Power
Sorting Cost ( By Jig )
32
IDR
49228/Hour
21-Dec-20
Hour
1,575,296.00
22-Jan-21
DN/HIAM
29-Jan-21
S/21/025
OPEN
GW
Material
Special Jig
21-Dec-20
22-Jan-21
DN/HIAM
29-Jan-21
S/21/025
OPEN
GW
IDR
21-Dec-20
6,868,129.00
22-Jan-21
DN/HIAM
29-Jan-21
S/21/025
OPEN
GW
IDR
12/21/2020
26,654,115.40
1/22/2021
DN/HIAM
29-Jan-21
S/21/025
OPEN
GW
Material
2
Master Cylinder Finish 139
Total
CONFIDENTIAL
200000/Pcs
49411/Pcs
IDR
400,000.00
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
33
4. Outgoing, Process & Incoming Quality Control.
4.6. Returned Material Approval (RMA).
Action
Month
Supplier
Part Name
BMT Cap Reservoir
Problem
Over Buffing
QI
IQC-QIL12-20-006
QA SUPPLIER APPROVAL
Unit price
(IDR)
Qty
BMT
7-Jan-21
DN/HIAM
21-Jan-21
S/21/023
OPEN
BMT
1/6/2021
1/7/2021
DN/HIAMS
21-Jan-21
/21/023
OPEN
BMT
6-Jan-21
18-Jan-21
DN/HIAM
20-Jan-21
S/21/022
OPEN Kohwa
1/6/2021
1/18/2021
DN/HIAMS
1/20/2021
/21/022
OPEN
25-Jan-21
25-Jan-21
DN/HIAM
29-Jan-21
S/21/024
OPEN NICHRIN
1/25/2021
1/25/2021
DN/HIAMS
29-Jan-21
/21/024
OPEN
26-Jan-21
27-Jan-21
DN/HIAM
29-Jan-21
S/21/026
OPEN Grakindo
1/26/2021
1/27/2021
DN/HIAMS
29-Jan-21
/21/026
OPEN
7.35
Hour
49228/Hour
IDR
361,825.80
6-Jan-21
7-Jan-21
Material
Screw Flat
666
Pcs
98/Pcs
IDR
65,268.00
6-Jan-21
IDR
427,093.80
Sorting Cost
3.2
49228/Hour
IDR
157,529.60
Approval date Invoice NO Issue Date
Payment
Date
IQC-QIL12-20-007
Material
Nichirin Hose Brake
OPEN
Repair Cost
Issue date
IDR
157,529.60
Total
Tonjolan Area
Hose end
DN/HIAM
21-Jan-21
S/21/023
Man Power
Man Power
Rusty
PIC /
Supplier
Detail action
Total
Kohwa Piston Master
Status
Scrap , Man
Power , Tool ,
Material
Dec-20
ISSUE DEBIT NOTE
Amount
(IDR)
Brake set assy k59
1 Set
390995/Set
IDR
390,995.00
Kohwa
IQC-QIL01-21-004
IDR
390,995.00
Total
NICHRIN
Jan-21
Material
Grakind
Union Bolt
o
Scratch di area
Flange
Brake set assy k59
1 Set
390995/Set
IDR
390,995.00
IQC-QIL01-21-005
Total
CONFIDENTIAL
IDR
390,995.00
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
Grakindo
34
4. Outgoing, Process & Incoming Quality
Control.
4.7. Holding Parts (Astemo) AS – GW Master & Caliper Cylinder Finish.
HOLDING PARTS HIAMS-AS ( GW ) MASTER & CALIPER CYLINDER FINISH
Action
No
Part Name
Problem
Propose Debit Note
Qty
Sorting
Touch Up
Clean Up
Painting
Remark
Status
Repair for Burr
( All part can use )
Close
Other
1
Master Cylinder
Finish
Burr Inside ID
( G area )
1373
2
Master Cylinder
Finish
Burr Inside ID
( End of Tapping )
740
740
Need maximum
spec for size of Burr
Close
3
Master Cylinder
Finish
Air Vent
1040
1040
Machine Adjust
Close
4
Caliper Cylinder
Finish
Piston Load
Problem
( Machining Line
C&D )
4347
4374
66 Pcs Can't Reuse
Close
5
Caliper Cylinder
Finish
Innovalues Part
10492
10492
Waiting Approval
GCN
Open
Sorting Result :
Total Check :
107917
OK : 107778
NG : 139 ( 0.12 % )
Open
6
Mater Cylinder Finish
Dimension 53
107917
mm Out of Spec.
1373
107917
CONFIDENTIAL
Repair Cost to Charge to GW
On progress D/N
Can't Reused part will charge to GW
Repair Cost to Charge to GW
On progress D/N
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
35
5. SQM Activity.
5.1. Supplier Performance (PPM & Quality Rank).
No
Supplier
code
or
G&G Code
1
241577
2
867374
3
Quantity Rejected FY2020
Supplier Name
Quality
Rank
( Jan'21 )
Apr-20
May-20
Jun-20
Jul-20
Aug-20
Sep-20
Oct-20
Nov-20
Dec-20
Jan-21
Feb-21
Mar-21
Total
0
0
0
0
0
0
0
0
0
0
0
0
0
S
0
0
0
25
588
250
882
1
391
42
0
0
2179
D
864356
ALPS ELECTRIC (MALAYSIA) SDN. BHD.
BUMIPUTERA MANUFAKTUR TEKNOLOGI,
PT
DHARMA POLIMETAL, PT
0
0
1
0
1
1
2039
0
5
0
0
0
2047
S
4
692473
FUKOKU TOKAI RUBBER INDONESIA, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
5
687394
FUJI SPRING INDONESIA, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
6
665443
GARUDA METALINDO, PT TBK
0
0
0
0
0
0
0
0
0
0
0
0
0
S
7
10414
HIAMS -AS GW THAILAND
0
0
0
0
14
1413
0
2
0
0
0
0
1429
S
8
10414
0
0
0
0
0
0
0
0
0
0
0
0
0
S
9
683684
0
0
0
0
0
0
0
0
0
0
0
0
0
S
10
592358
SHOWA DENKO
KIYOKUNI HIGH PRECISION AUTOMOTIVE
INDONESIA, PT
KOHWA PRECISION INDONESIA, PT
0
0
0
0
0
0
0
0
29
0
0
0
29
S
11
687029
KOMATSU BANE INDONESIA, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
12
10413
MURAKOSHI JAPAN
0
0
0
0
0
0
0
0
0
0
0
0
0
S
13
683384
NICHIRIN INDONESIA, PT
0
0
0
1
0
0
33
1
3
3
0
0
41
D
14
725057
NOK INDONESIA SALES, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
15
683683
OCHIAI MENARA INDONESIA, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
16
534832
RHYTHM KYOSHIN INDONESIA, PT
0
0
0
0
9
0
1116
9
0
0
0
0
1134
S
17
535418
SANWA ENGINEERING INDONESIA, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
18
703297
SIGMA & HEARTS INDONESIA, PT
0
0
73
555
1875
14
0
0
2
9
0
0
2528
C
19
693932
KURODA ELECTRIC INDONESIA, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
20
10413
TAGA JAPAN
0
0
0
0
0
0
0
0
0
0
0
0
0
S
21
10413
TAKECHI JAPAN
0
0
0
0
0
0
0
0
0
0
0
0
0
S
22
10413
WATANBE JAPAN
0
0
0
0
20
0
0
0
0
0
0
0
20
S
23
898696
GRAKINDO MAJU SUKSES, PT
0
0
1
0
0
10
0
4
0
2
0
0
17
C
24
898701
SUGINDO INTERNATIONAL, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
25
898700
PDF PRESISI ENGINEERING, PT
0
0
0
0
0
0
0
0
0
0
0
0
0
S
0
0
75
581
2507
1688
4070
17
430
56
0
0
0
#DIV/0!
44
164
673
363
910
5
97
9
Total
CONFIDENTIAL
9424
272.24
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
36
5. SQM Activity.
5.2. Worst Supplier Performance Monitoring.
Worst Supplier Ranking List (1H20)
Worst
Ranking
Supplier Code
Name of Company
Total
Score
1
0000703297
SIGMA & HEARTS
INDONESIA, PT
78
2
0000864356
DHARMA
POLIMETAL, PT
90
3
0000867374
BUMIPUTERA
MANUFAKTUR
TEKNOLOGI, PT
4
0000011676
5
Rating
(Class)
Monitoring Worst Supplier Performance
Oct-20
Rating
Score
( Class)
2H20
(Avg)
Rating
(Class)
92.5
B
(Fair)
100
B
(Fair)
91
B
(Fair)
77
92.2
B
(Fair)
74.25
D
(Worst)
70
HIAMS -AS GW
THAILAND
93
B
(Fair)
96.75
A
(Good)
100
0000683384
NICHIRIN
INDONESIA, PT
94
B
(Fair)
85
C
(Poor)
100
6
0000898696
GRAKINDO MAJU
SUKSES, PT
94
B
(Fair)
91.75
B
(Fair)
7
0000534832
RHYTHM KYOSHIN
INDONESIA
96
A
(Good)
86.75
C
(Poor)
D
(Worst)
S
(Excelent )
D
(Worst)
D
(Worst)
Nov-20
Rating
Score
( Class)
100
100
72
S
(Excelent )
S
(Excelent )
D
(Worst)
Dec-20
Rating
Score
( Class)
85
C
(Poor)
85
C
( Poor )
87
C
(Poor)
100
S
(
Excellent
)
78
D
(Worst)
100
S
(
Excellent
)
68
D
(Worst)
80
C
( Poor )
100
S
( Excelent
)
77
87
C
( Poor )
100
S
(Excelent
)
87
C
( Poor )
85
100
S
(Excelent
)
87
C
( Poor )
100
67
D
(Worst)
80
C
( Poor )
100
S
(Excelent )
CONFIDENTIAL
Jan-21
Rating
Score
( Class)
D
(Worst)
S
(Excelent )
C
(Poor)
S
(Excelent )
S
(Excelent
)
Feb-21
Rating
Score
( Class)
Mar-21
Rating
Score
( Class)
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
37
5. SQM Activity.
5.3. Supplier Improvement Activity.
Worst
Ranking
Name of Company
1H20
( Score )
Major Problem
2H20
(Target)
Action
Due Date
Status
1. Check 100% for concentricity item before input to Machining Process ( Still continue check )
Dec'20
Close
2. Additional machining process for inner diameter
Dec'20
Close
3. Management Improvement Activity
Mar'21
On Progress
Jan'21
Continue
1. Made Quality warning deeping time chromating in upper range ( Standard 4-5 Minute )
Oct'20
Close
2. reduce quantity part in the deping process in lower range ( Standard 35-45 kg/Barel )
Oct'20
Close
3. Management Improvement Activity
Mar'21
On Progress
1. BMT will conduct an internal audit & Subcont audit, especially in the QA Dept
Dec'20
Close
Every Week
Continue
Dec'20
Close
4. Check 200 % All part for 3 months until get rank s 3 times
Start Dec'20
Continue
5. QC Patrol by SPV up
Start Dec'20
Continue
6. Management Improvement Activity
Mar'21
On Progress
Supplier Action:
1. Revise Process Control Plan addition item control pressure and Flow rate .
2. Review PFMEA item Burr or contamination remain after Washing process.
3. Revise Machine check sheet addition item control at Washing machine.
4. Repair high pressure washing pump
5. Addition item to PM plan
6. Lesson learn this trouble to Caliper product at high pressure washing machine.
Sep'20
Close
Start Dec'20
Continue
Supplier Action :
1
SIGMA & HEARTS
INDONESIA, PT
78
Machining Problem
( Concentricity Problem
effect from Forging Part )
> 95
Hitachi Action :
1. Tightening inspection 30 Pcs/Lot delivery for item Concentricity
Supplier Action :
2
DHARMA POLIMETAL, PT
90
Plating Problem
> 95
2. Continue Report Quality Problem every Week
3
4
BUMIPUTERA
MANUFAKTUR
TEKNOLOGI, PT
HIAMS -AS GW
THAILAND
3. carry out QCC activities for Quality Improvement
92.2
93
Painting Problem
Machining Problem
( Burr Inside ID )
> 95
> 95
Hitachi Action:
Weekly meeting QA Hitachi and GW every Friday
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
38
5. SQM Activity.
5.3. Supplier Improvement Activity.
Worst
Ranking
5
Name of Company
NICHIRIN INDONESIA, PT
1H20
( Score )
94
Major Problem
Assembly Process Problem
( Hose end Mixing )
2H20
(Target)
Action
Due Date
Status
1. make OPL in process acsesories mention crimping 1
Nov'20
Close
2. Change the marking position, both crimping have to marking
Nov'20
Close
1. Re-Training to technican related WI Setting
Nov'20
Close
2. Modification Dies related problem Union bolt dented
Nov'20
Close
3. Check 200% in Hitachi for old stock and monitoring quality judgement for Final Inspection in Grakindo ( Skill Up )
Dec'20
Close
4. Management Improvement Activity
Mar'21
On Progress
1. Re-Training to Inspector Related WI and Limit sample
Nov'20
Close
2. Modification Shutter at stamping proses for reducing dented on Washer
Dec'20
Close
3. Add Operator Indentify on Part label for monitoring
Dec'20
Continue
4. Management Improvement Activity
Mar'21
On Progress
> 95
3. Check 200% in Hitachi for monitoring quality judgement for Final Inspection in Grakindo ( Skill Up )
4. Management Improvement Activity
6
7
GRAKINDO MAJU
SUKSES, PT
RHYTHM KYOSHIN
INDONESIA
94
96
Forging Problem
Molding & Stamping
Problem
> 95
> 95
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
39
5. SQM Activity.
5.3.1 Supplier Improvement Activity.
Supplier Management Improvement Activity
PT. BUMIPUTERA MANUFAKTUR TEKNOLOGI
1. Automatic Process treatment machine
to get a more accurate processing time
CONFIDENTIAL
2. Management Tool: Change tool
storage from manual to automatic to
simplify the traceability of tool changes
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
40
5. SQM Activity.
5.3.1 Supplier Improvement Activity.
Supplier Management Improvement Activity
PT. BUMIPUTERA MANUFAKTUR TEKNOLOGI
3. Monitoring 200 % Check in Hitachi and create operator performance reports
from the results of 200% check, to find out which operators need to be fixed
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
41
5. SQM Activity.
5.4. Supplier Quality Audit.
Online Audit (Ms. Team)
No
1
Supplier Name
PT. Dharma Polimetal
Periode
PLAN
ACTUAL
2
PT. Nichirin Indonesia
PLAN
ACTUAL
3
4
PT. Kiyokuni High Precision
Automotive Indonesia
PT. Kohwa Precision Indonesia
PLAN
ACTUAL
December'20
I
II
PT. Rhythm Kyoshin Indonesia
PT. Komatsu Bane Indonesia
7
PT. Sigma & hearts Indonesia
II
III
February'21
IV
V
I
II
III
March'21
IV
I
II
III
IV
Part 1
Part 2&3
Part 4
V
1-Dec
2-Dec
2-Feb
24-Mar
Part 1
Part 2&3
Part 4
2-Dec
2-Dec
22-Feb
24-Mar
Part I
Part 2&3
Part 4
18-Dec
26-Feb
25-Mar
Part 1
Part 2&3
Part 4
2-Dec
18-Dec
16-Dec
1-Mar
25-Mar
Part 1
Part 2&3
Part 4
7-Dec
5-Mar
25-Mar
Part 1
Part 2&3
Part 4
PLAN
ACTUAL
I
24-Mar
PLAN
PLAN
V
8-Feb
ACTUAL
6
IV
1-Dec
ACTUAL
5
III
January'21
16-Jan
8-Dec
8-Mar
26-Mar
Part 1-3
Part 4
25-Jan
8-Mar
26-Mar
Part 1
Part 2-3
Part 4
PLAN
ACTUAL
8
9
PT. Fukoku Tokai Rubber
Indonesia
PT. Fuji Spring Indonesia
PLAN
ACTUAL
PLAN
ACTUAL
10
PT. Kuroda Electric Indonesia
PLAN
ACTUAL
11
PT. NOK Indonesia Sales
PLAN
ACTUAL
25-Jan
18-Dec
15-Mar
26-Mar
Part 1
Part 2&3
Part 4
18-Jan
17-Dec
19-Mar
29-Mar
Part 1
Part 2&3
Part 4
22-Mar
29-Mar
Part 2&3
Part 4
17-Jan
15-Jan
Part 1 &
2
15-Jan
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
42
5. SQM Activity.
5.4. Supplier Quality Audit.
Part 1 Analysis of Customer Quality Information & Specific Requirements from Customer
Audit Time
No
10
11
Supplier
PT. NOK
INDONESIA
PT. FTR
Date
15-Jan-21
25-Jan-21
Audit Methode
9:30-11:10
9:30-12:00
Online
( Part 1 )
Online
( Part 1 )
Audit Result
Audittor
Auditee
Bapak Hamidi ( QA )
Bapak Fratanto ( QA )
Nana Sukarna
Ibu Nurulah ( QA )
Inu Widi ( QA )
Bapak Fratanto ( PU )
Nana Sukarna
No.
Category
1
Mayor
1
Minor
Bapak Sunaryo ( MFG )
Bapak Agus ( QA )
Bapak Imam ( QA )
2
CONFIDENTIAL
Mayor
Item
Observations /
Requests
Duedate
- SQM is not running
properly.
- There is no
Specific
evidence of a review
Requirement From
29-Jan-21
of SQM 4.3
Costumer
- Not yet created a
CSR Matrix (SQM
Hitachi)
Doc. Control
There is no external
document control
procedure
5-Feb
- SQM is not running
properly.
- There is no
Specific
evidence of a review
Requirement From
5-Feb-21
of SQM 4.3
Costumer
- Not yet created a
CSR Matrix (SQM
Hitachi)
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
43
3
7
PT.Kohwa
Precision
Indonesia
√
Change To
√
PT. Diameteral
Piston Caliper
Involute
Multisourch supplier
√
PT. Diameteral
Piston Master
Involute
Multisourch supplier
( Prototype Part )
√
PT. Bumiputera
Manufaktur
Teknologi
√
PT. Ochiai
Menara
Indonesia
Lever
Washer Pin
Additional dies #8
Change Supplier Plating From
KPD --> Hotmal
OK
4th Week on
Nov'20
Mar'21
Mar'21
Mar'21
Feb'21
Feb'21
Plan
Actual
19-Oct > 16Nov
14-Oct > 16Oct
Result
Plan
Actual
Result
Plan
Actual
Result
NG > OK
Plan
20-Nov
IPL ( Initial Part
Label )
Result
PPA & Use
Instruction
4-Sep'20
JFE-->Tokuden-->Nakagawa-->KPI
Piston Master
Actual
03-Mar & 27Mar
03-Mar & 27Mar
Plan
Customer
Approval
Additional dies #5
Plan / Actual
Product
Testing
Caliper Machining Adding
Procces Sub Cont ( Innovalues )
Due Date
Process
Production
Caliper Cyl
Finish
Reason of Change
Part
Measurement
Part Name
PT. Bumiputera
Manufaktur Holder Cable
Teknologi
√
5
6
Hitachi
Automotive
System Asia (
GW )
√
4
Supplier Name
Testing Part
2
P3TI ( Part/Product/Procces Trial Instructions )
Material
Testing
1
New Supplier
No
PCR
Category
-
11-Mar
11-Aug
12-Aug
18-Sep'20
21-Sep'20
21-Sep'20
-
11-Mar
10-Aug
11-Aug
-
OK
NG
19-Oct
-
Jan'21
19-Oct
-
OK
-
Jan'21
14-Jan'21 15-Jan'21 2-Dec'20 15-Jan
15-Jan
OK
Jan'21
OK
ok
-
31-Jan
-
Result
OK
-
Plan
18-Dec
Jan'21
Actual
18-Dec
18-Dec 28-Jan'21
Result
Plan
Actual
Result
OK
Jan'21
29-Jan'21
OK
Jan'21
OK
Feb'21
Feb'21
Open
Feb'21
Feb'21
Open
Mar'21
Mar'21
Already submit to AHM Waiting
Customer Approval
Feb'21
Open
11-Dec
Remaining testing
result from supplier
18-Nov
OK
-
11-Dec
Close
OK
20-Nov 20-Nov 20-Nov Mar'21 Mar'21 Feb'21 Mar'21 Mar'21
4-Nov 14-Jan'21 14-Jan'21 Already submit to AHM Waiting
Customer Approval
OK
OK
OK
16-Nov 20-Nov 20-Nov Jan'21 Jan'21 Jan'21 Jan'21 Jan'21
Already submit to AHM Waiting
13-Nov 20-Nov 20-Nov
Customer Approval
OK
OK
OK
Actual
CONFIDENTIAL
Waiting GCN Approval Open
Jan'21
OK
Jan'21
Over All Status
6. New Development/Engineering Change Control
Feb'21
Feb'21
Feb'21
Waiting Adhesion test from Supplier
Open
Feb'21
Open
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
44
7. Others
7.1 Internal Audit Planning
Background: IATF 16949 (and ISO 9001) requirements clause no. 9.2 about internal audit and instruction
from QM Division related to Production Process Audit and Internal Special Quality Audit.
Process
Process Audited
Owner
Corporate Strategy
01-Mar 02-Mar 03-Mar 04-Mar 05-Mar
QMS
⃝
SALES
⃝
Product & Process Design/Customer Project
CFT
⃝
Control of Changes
PDE
⃝
Quality Control Process
QA
⃝
Nonconformity Management & Calibration
QA
⃝
Production Planning
PC
Manufacturing
PD
Logistic Management
PC
⃝
AR/AP Management
FA
⃝
Purchasing Management
PU
⃝
Human Resources Management
HR
⃝
Machine Facilities & Infrastructure Management
MT
⃝
Document Management
DC
⃝
Customer Related Management
CONFIDENTIAL
⃝
⃝
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
45
7. Others
7.2 Global Quality Operating System SASG Implementation
Objectives: Global QMS standardization for Astemo Gr. by implementation of SASG.
Future plan: All internal standard/documentation will be replaced by SASG.
CONFIDENTIAL
© PT. Hitachi Astemo Bekasi Brake Systems. All rights reserved.
46