LECTURE NOTE
LECTURE NOTE
1. Employees’ effort and ability are valuable
resources and beneficial to the organization.
2. To achieve company’s growth we shall promote
employees commitment and sense of ownership.
1. Employees’ effort and ability are valuable
resources and beneficial to the organization.
2. To achieve company’s growth we shall promote
employees commitment and sense of ownership.
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
3. When employees are committed, they are ready
to be developed through training programs hence
increase their involvement in achieving company’s
goals.
3. When employees are committed, they are ready
to be developed through training programs hence
increase their involvement in achieving company’s
goals.
1. Generate Cost Savings & Increase Profit
2. Increase Effectiveness and Efficiency
1. Generate Cost Savings & Increase Profit
2. Increase Effectiveness and Efficiency
POTENTIAL BENEFITS
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
2. Increase Effectiveness and Efficiency
3. Promote Teamwork & Sense of Ownership
4. Enhance Employees’ Career Development
2. Increase Effectiveness and Efficiency
3. Promote Teamwork & Sense of Ownership
4. Enhance Employees’ Career Development
1. Employee Suggestion Scheme (ESS)
2. On Job Training (OJT)
1. Employee Suggestion Scheme (ESS)
2. On Job Training (OJT)
INITIATIVES RELATED
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
3. Employee Recognition Program
4. Employee Competency Program
5. Continuous Improvement Program
6. Autonomous Maintenance (AM)
3. Employee Recognition Program
4. Employee Competency Program
5. Continuous Improvement Program
6. Autonomous Maintenance (AM)
1. AM refers to the activities where the operators perform basic
maintenance activities independent of the maintenance department.
2. The AM activities consist of:
2.1 5S
2.2 Daily inspections
AUTONOMOUS MAINTENANCE
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
2.2 Daily inspections
2.3 Lubrication
2.4 Parts replacements
2.5 Simple repairs
2.6 Abnormality detection
2.7 Precision check.
1. The goal of AM initiative is to develop knowledgeable
operators who will be responsible to ensure :
a) Prevention to equipment deterioration.
b) Restoration of equipment to its ideal state.
AUTONOMOUS MAINTENANCE
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
c) Basic conditions are established to maintain equipment.
2. As the shop-floor become more orderly, any abnormal condition
(fuguai) can be detected at a glance.
Zero Accident + Zero Defect + Zero Downtime
Prevention
1. Ultimately, this program will bring the company to achieve zero breakdown, zero
defect, and zero accident.
AUTONOMOUS MAINTENANCE
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
Knowledgeable
OperatorsOptimal Equipment
Condition
Orderly
Shop-floor
Orderly
Shop-floor
Prevention
Occurrence of
abnormalities
Occurrence of
abnormalitiesIndication of abnormalitiesIndication of abnormalities
1. There are 7 steps in AM and operators shall be trained on each step. Audits shall be
carried out periodically to determined the AM teams progression to the next step.
2. The AM activities shall be supported by Maintenance or other supporting department
personnel.
Step 7– Autonomous SupervisionAudit
Training
Do AM
Audit
AUTONOMOUS MAINTENANCE
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
Step 1- Cleaning as inspection, lubrication and tightening
Step 2 – Countermeasures to source of contamination
Step 3 – Cleaning and Lubricating Standard
Step 4 – Overall Inspection Standard
Step 5- AM Standards Zero Breakdown.
Step 6– Process Quality Assurance
Training
Do AM
Audit
Training
Do AM
AuditTraining
Do AM
Audit Training
Do AM
Audit
Training
Do AM
1. Employee Suggestion Scheme is a program where the employees are
encouraged to suggest improvement ideas to the company.
2. The company will benefit when employees voluntarily think about innovative,
creative and effective improvement ideas - that can be implemented in the
company as well as at other subsidiaries.
EMPLOYEE SUGGESTION SCHEME
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
3. These ideas can be implemented either by the idea owner or by other
personnel who work as a team with the idea owner.
4. ESS program will be coordinated by a team of ESS Committee.
5. The ESS Policy will state the guideline to manage the ideas and the
rewards.
6. Potential Cost Saving and Actual Cost Saving must be monitored and
verified by the Finance personnel.
Signal our recognition to the employee
Different “eyes”
see clearer
We are so use to our work problem missour attention.
EMPLOYEE SUGGESTION SCHEME
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
WHY
GIVE
IDEA?
Encourage
Continuous
Improvement
To The
Employees
Encourage
employee to
enquire skill
and knowledge
Boost
employees
morale
1. Skill chart is a method for monitoring and
identify the workers skill by the process.
SKILL CHART
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
2. This will helps leader to manage worker
skill and conduct proper work
arrangement in On-Job-Training (OJT).
Skill Chart Development
a) Separate the department into smaller section and group for proper
monitoring, evaluation and training.
b) Identify each group process flow includes the sub and indirect
processes.
SKILL CHART
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
c) Categorized worker into 4 main stages of competency:
- Understand the work process.
- Carry-out job with guidance or supervision.
- Carry-out job without guidance and supervision.
- Able to teach others.
d) Develop a visual monitoring table for each member in the group.
e) Set a frequency for evaluation and updating the skill chart
Skill Chart Implementation
② Group process is clearly
identified and placed on the
skill chart.
① Clearly state the group,
③ Group name and
process to be clearly stated
SKILL CHART
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
① Clearly state the group,
section, department
information, last evaluation
date and frequency of
evaluation.
④ Team leader to identify
his subordinates name &
employee no.
⑤ Team leader shall update
the skill level based on the
degree of achievement and
test report shall be kept by
the group.
005004003002 Sub2Sub1001NameNo
Xx times/yearFrequency
DD-MM-YYYYLast Evaluation Date
XXXXXGroup
XXXXXXXSection
XXXXXXXXXDepartmentProcess Skill Chart Control ListProcess/Group: 001 ~ 005
001 002 003 004 005
Sub1 Sub2
Understand
Process Control Skill Chart List
SKILL CHART
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
DDD DDD4
CCC CCC3
BBB BBBB2
AAA AAAA1
Able to
teach
others
Carry out
job without
supervision
Carry out
job with
supervision
Understand
the work
process
1. A competency is defined as a behaviors that describes excellent
performance in a particular job.
2. The competency will help each company with key problems such as
to:
2.1 Clarifying the workforce standards and expectations
MANUFACTURING COMPETENCY
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
2.1 Clarifying the workforce standards and expectations
2.2 Creating empowerment, accountability and alignment ofcoach, team member and employer in performancedevelopment.
2.3 Aligning individuals, team and managers against thecompany vision, mission and values.
1. Differences between Competency, Skill and Knowledge
2. A competency is the capability to use of related knowledge, skills,
and attitude/abilities required to perform "critical work functions" or
tasks.
MANUFACTURING COMPETENCY
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
3. Competencies shall serve as the basis for skill standards that
specify the level in 3 major elements:
�Knowledge
�Skills
�Abilities/Attitude
Attitude/
Abilities
Desire to do an
excellent job
Competency
Meets all commitments in
timely manner
MANUFACTURING COMPETENCY
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
Skill Knowledge
Competency
Capability from
experience and
education
Capability to
perform action to
achieve the
desired outcome
Competency
Perform to job accurately
without error
Competency
Perform to job efficiently
within stipulated time
There are 2 types of CIP :
QIT
Continuous Improvement Program (CIP) is important to an organization where the
management and non-management staff participate in carrying out improvement in
relation to Quality, Cost, Delivery, Safety and Morale (QCDSM). When employees
are involved with continuous improvement activities they will contribute to the
company’s productivity growth.
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
1. Continuous Improvement Program
ICC
There are 2 types of CIP :
� Innovative Creative Circle (ICC)
Participated by the shopfloor and non-
management staff.
�Quality Improvement Team (QIT)
Participated by the management staff
QIT
Non Management
Management
Continuous Improvement Program (CIP)
Both CIPs are top-down driven where the management staff will carry out these
initiatives prior to cascading down to their subordinates.
They will formed models that will be samples and reference for others. The
management staff are also expected to be one of the facilitators or mentors once
these initiatives are deployed to different level.
P2 – TOTAL EMPLOYEE INVOLVEMENT AND DEVELOPMENT
1. Continuous Improvement Program
Non-ManagementNon-Management
• Technicians
• Supervisors
• Line Leaders
• Operators
• Technicians
• Supervisors
• Line Leaders
• Operators
I C CI C C
• Managers
• Assistant Managers
• Engineers
• Executives
• Managers
• Assistant Managers
• Engineers
• Executives
ManagementManagement
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LONG TERM BUSINESS THINKING 1
TOTAL EMPLOYEE INVOLVEMENT & DEVELOPMENT2
VISUAL MANAGEMENT3
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