Production Manager  •  PT. Coats Rejo Indonesia

Januari 1994 - Desember 2007

PT. Coats Rejo Indonesia – Bogor, A United Kingdom based Multinational Manufacturing Company, the largest sewing threading the world operates in more than 50 countries around the world. A subsidiary in Indonesian has 2 units in Bogor and Pasuruan (East Java) with 1023 employees.

Scope:
Involved with the planning, coordination and control of manufacturing processes. They ensure that goods and services are produced efficiently and that the correct amount is produced at the right cost and level of quality.
1. Overseeing the production process, drawing up a production schedule
2. Ensuring that the production is cost effective
3. Making sure that products are produced on time and are of good quality
4. Working out the human and material resources needed
5. Drafting a timescale for the job
6. Estimating costs and setting the quality standards
7. Monitoring the production processes and adjusting schedules as needed
8. Being responsible for the selection and maintenance of equipment
9. Monitoring product standards and implementing quality-control programmers
10. Liaising among different departments, e.g. suppliers, managers
11. Working with managers to implement the company's policies and goals
12. Ensuring that health and safety guidelines are followed
13. Supervising and motivating a team of workers
14. Reviewing worker performance
15. Identifying training needs
16. Control final process
17. Manage 502 persons of subordinates
18. Set up machinery for a new machine in Production
19. Control spare parts and material stock
20. Control maintenance and a setting program on the machines
21. To develop production system to increase productivity by 38% in 3 months with the same resources
22. With QA department and Marketing department did customer satisfaction policy by visit, answer and help their complaint and techniques problem
23. Making production plan of customized orders
24. Support sales and marketing

Experience in:
25. Increased productivity from 18,000 clues/ day to 22,000 clues/ day in 3 months.
Whit this Department / this company I learned about management in very dynamic bulk production system that need a fast switch time of model. In 3 month I could hit a target which never been achieved before by re-arrange people working system and a little modification in machinery. And also how to execute and manage an expansion plan which gives additional subordinates from 288 people to 502 people with many various machinery type. I also analyze weakness area and give a specific training for every operator with different type of machine. Make a harmony between new workers with existing worker is something new for me and it pleased me that I was quiet success on that.
Our main business is to sell color thread. This job is to convert gray thread into color thread as per customer request (within specific tolerance) and ensure on time delivery.
Organize all resource to finish job order as scheduled by Logistic on timely basis. This will involve activities like job card printing, recipe screening, dye lot scheduling, beacon control, dyes/ chemical dispensing, dyeing, pass/ fail, tracking into VB-Vital. Provide dyeing procedures. Organize color standard, evaluate dyeing and employee performance to achieve the above set objectives.
This job involve the use of 40 units dyeing machines with 2 Beacon scheduler, 4 computer to run CF2000E software with 4 Spectrophotometers (US $ 100,000), 3 Ahiba Lab Dyeing machines ( US $ 80,000 ), and 2 units automatic dispensing ( US $ 100,000) and 1 unit Color Talk system for color communication (US $ 60,000).
The whole system operated by 110 employees. We produced on average 8,000 Kg thread or US $ 48,000 per day.
Annual cost of dyestuff and chemicals was about US $ 900,000.

Achievements:
- To achieve height RFT dyeing as set by group ( > 97 % )
- To achieve height LpMpD dyeing as set by group (>10 lot / mc at 80 % utilization).
- To achieve height color quality with CMC dE< 1.2 set by group (> 93%).
- To achieve height production throughput ( 100 % at 3 day )
- To achieve height customer complaint ( < 0.5 % )
- To achieve height Lead Time ( < 5 days )
- To achieve Fastrack order ( > 97 % )