IMPROVEMENT AND IMPLEMENTATION OF PRODUCTION TRAINING CENTER AT A GERMAN AUTOMOTIVE MANUFACTURING COMPANY
By
REYNALDI WIJAYA 1-1607-002
BACHELOR’S DEGREE in
INDUSTRIAL ENGINEERING
FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY
The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera
Tangerang, Banten 15143 - Indonesia
JULY 2020
Revision after Thesis Defense on 6th July 2020
Reynaldi Wijaya I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Reynaldi Wijaya
Date
Dr. Tanika Dewi Sofianti, S.T., M.T.
Date
Ir. Setijo Awibowo, M.M.
Date
Dr. Maulahikmah Galinium, S.Kom, M.Sc
Date Student
Approved By:
Thesis Advisor
Thesis Co-Advisor
Dean of Faculty of Engineering & IT
Reynaldi Wijaya ABSTRACT
IMPROVEMENT AND IMPLEMENTATION OF PRODUCTION TRAINING CENTER AT A GERMAN AUTOMOTIVE MANUFACTURING COMPANY
By
Reynaldi Wijaya
Dr. Tanika Dewi Sofianti, ST.MT, Advisor Ir. Setijo Awibowo, M.M., Co-Advisor
SWISS GERMAN UNIVERSITY
Automotive manufacturer all over the globe has been striving to perfect their manufacturing technique from time to time, allowing them to become more effective. This goal is attributed to the effective management of the company’s resources, especially it’s human resource knowledge. Companies are able to improve its organization to meet challenging business needs by making the best use of information available in a company. This system is called Knowledge Management where information within a company is organized to be created, shared, used, and managed by the company.
PT. XYZ factory currently has no means of an organized worker training program which leads to long training hours for workers. To solve the problem, previously designed training center by the company are to be improved and fully implemented. The research method utilized in this thesis is the ADDIE model which consists of 5 steps, which are analyze, design, development, implementation, and evaluation. The research managed to improve and implement the training center design, as shown by implementing the training center area and its E-Learning application. It allows the company to manage the knowledge of human resources by recording knowledge found from external and internal sources and distribute the recorded knowledge to the workforce in an effective and efficient manner.
Keywords: Knowledge Management, ADDIE Model, E-Learning, Learning Factory, Training
Reynaldi Wijaya
© Copyright 2020 By Reynaldi Wijaya
All rights reserved
Reynaldi Wijaya DEDICATION
I dedicate this thesis to my parents
Who have allowed their son to achieve his dreams
Reynaldi Wijaya ACKNOWLEDGEMENTS
I would like to express my utmost gratitude towards Wahyu Ricardo S.T. and Rezky Dwimarsya, S.T. B. Eng., who have tirelessly guided me in the thesis project for the past months even with their hectic schedule. Their guidance in these tough times, without doubt, allowed me to finish this thesis project.
Reynaldi Wijaya TABLE OF CONTENTS
STATEMENT BY AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 10
LIST OF TABLES ... 12
CHAPTER I – INTRODUCTION ... 13
1.1. Background ... 13
1.2. Research Problems ... 14
1.3. Research Objectives ... 14
1.4. Research Limitations ... 14
1.5. Research Structure ... 14
CHAPTER II – LITERATURE REVIEW ... 16
2.1. Knowledge Management ... 16
2.1.1 Types of Knowledge ... 16
2.1.2. Knowledge Conversion ... 17
2.2. Information Hierarchy ... 18
2.2.1. Data ... 19
2.2.2. Information ... 19
2.2.3. Knowledge ... 19
2.2.4. Wisdom ... 19
2.3. Skill Matrix ... 19
2.4. Addie Model ... 19
2.4.1. Analysis Phase. ... 20
2.4.2. Design Phase ... 20
2.4.3. Development Phase ... 20
2.4.4. Implementation Phase ... 21
2.4.5. Evaluation Phase ... 21
2.5. Learning Factory ... 21
2.6. Rapid Application Development (RAD) ... 21
2.6.1. Analysis... 22
2.6.2. Prototyping Cycle ... 22
2.6.3. Test ... 23
Reynaldi Wijaya
2.7. Likert Scale ... 24
CHAPTER III - RESEARCH METHODOLOGY ... 26
3.1. Analysis Phase ... 27
3.2. Design Phase ... 27
3.3. Development Phase ... 28
3.3.1. Configure E-Learning Application ... 28
3.3.2 Improve Training Centre Layout and Design ... 29
3.3.3. Improve Training Materials ... 29
3.4. Implementation Phase ... 29
3.5. Evaluation Phase ... 30
CHAPTER IV – TRAINING PROGRAM DESIGN AND DEVELOPMENT ... 31
4.1 Existing Problem on System ... 31
4.1.1. Current Condition of System ... 31
4.1.2. Previously Conducted Research ... 33
4.2. Job Description ... 34
4.2.1. Workstations of Vehicle Assembly Line ... 35
4.2.2. Competencies Required on the Assembly Line ... 35
4.3. Training Design ... 39
4.3.1. Training Curriculum ... 39
4.3.2. Improve Training Centre Layout and Facility Design ... 44
4.3.3. Configure E-Learning Application ... 45
CHAPTER V – IMPLEMENTATION OF TRAINING CENTER... 62
5.1. Implement Training Centre Design ... 62
5.1.1. Theoretical Area Implementation ... 62
5.1.2 Practical Training Area ... 64
5.2. Implement E-Learning application ... 66
5.2.1. First phase ... 66
5.2.2. Second Phase ... 66
5.3. User Acceptance Test ... 72
5.3.1. Respondents ... 72
5.3.2. Calculation with Likert Scale... 73
5.3.3. Result Analysis ... 83
CHAPTER VI - CONCLUSION AND RECCOMENDATION ... 84
6.1 Conclusion ... 84
6.2. Recommendations ... 85
REFERENCES ... 86
Reynaldi Wijaya
APPENDIX A – Special Parts Module ... 87
APPENDIX B – Tightening Presentation Module ... 104
APPENDIX C – CGIS Video Presentation ... 143
APPENDIX D – CS1 Guideline Video Presentation ... 154
APPENDIX E – I.O. Criteria Video Presentation ... 165
APPENDIX F – SOP Sample ... 171
APPENDIX G – SPL Sample ... 184
APPENDIX H – ApplicationTester ... 186
APPENDIX I – User Acceptance Test Questionnaire ... 188
APPENDIX J – Introduction Video for Application ... 201
APPENDIX K – Theoretical Area Information Board Content ... 203
CURRICULUM VITAE ... 205
Reynaldi Wijaya
CHAPTER II – LITERATURE REVIEW ... 16
Figure 2.1. - Model of Knowledge... 18
Figure 2.2. - Information Hierarchy ... 18
Figure 2.3. - ADDIE Methodology ... 20
Figure 2.4. - Rapid Application Development Methodology ... 22
CHAPTER III - RESEARCH METHODOLOGY ... 26
Figure 3.1. - Research Methodology... 26
Figure 3.2. - Analysis Phase Methodology ... 27
Figure 3.3. - Design Phase Methodology... 27
Figure 3.4. - Development Phase Methodology ... 28
Figure 3.5. - RAD Methodology to Configure E-Learning Application ... 29
Figure 3.6. - Implementation Phase Methodology... 29
Figure 3.7. - Evaluation Phase Methodology... 30
CHAPTER IV – TRAINING PROGRAM DESIGN AND DEVELOPMENT ... 31
Figure 4.1 - Trimming Line ... 35
Figure 4.2 - Mechanical Line ... 35
Figure 4.3 - Final Design of the Training Centre ... 44
Figure 4.4.- Registration Column for a New User on the Application ... 46
Figure 4.5.- Self Registration E-Mail Sent to New User ... 47
Figure 4.6.- Application’s Login Screen... 47
Figure 4.7.- Force Password Change After First Login Attempt ... 47
Figure 4.8.- Course Self Registration ... 48
Figure 4.9.- Course Appearance, Showing its Learning Materials and Activities ... 51
Figure 4.10.- Application’s Video Player for Video Presentation ... 52
Figure 4.11.- Example of a Course Presentation ... 52
Figure 4.12.- Example of a Course Module ... 53
Figure 4.13.- Essay Question on a Test ... 54
Figure 4.14.- Multiple Choice Question on a Test... 55
Figure 4.15.- Score Weight Setting on a Course ... 56
Figure 4.16.- Forum Threads on a Course Forum ... 56
Figure 4.17.- Operational Group Course ... 57
Figure 4.18.- SOP Database ... 57
Figure 4.19.- SPL Database ... 58
Figure 4.20.- Moodle Application View ... 59
Figure 4.21.- Mobile Web Application View ... 59
Reynaldi Wijaya
CHAPTER V – IMPLEMENTATION OF TRAINING CENTER ... 62
Figure 5.1.- Training Center Area... 62
Figure 5.2.- Theoretical Area ... 63
Figure 5.3.- View from Instructor’s Desk ... 63
Figure 5.4.- Tightening Operation Training Area ... 64
Figure 5.5.- Tool Cart and Information Board ... 64
Figure 5.6.- Material Basket ... 65
Figure 5.7.- Push-Pull Operation Training Area ... 65
Figure 5.8.- New Application Logo ... 66
Figure 5.9.- View of Course Presentation ... 68
Figure 5.10.- View of Course Video Presentation ... 68
Figure 5.11.- View of Course Module ... 69
Figure 5.12.- Result of Test Implementation ... 70
Figure 5.13.- Grading a Submitted Essay Question ... 70
Figure 5.14.- Grade Report of a Course ... 70
Figure 5.15.- A Worker Discussing Course Materials in the Forum ... 71
Figure 5.16.- Discussion in a SPL Entry... 71
Figure 5.17.- Worker’s Total Work Duration Chart ... 72
Figure 5.18.- Worker’s Position on Assembly Line Chart ... 73
Reynaldi Wijaya
CHAPTER IV – TRAINING PROGRAM DESIGN AND DEVELOPMENT ... 31
Table 4.1. Comparison of Research Achievements ... 34
Table 4.2. Competency Code Table ... 39
Table 4.3. Trimming Line Competency Matrix ... 40
Table 4.3. Trimming Line Competency Matrix (continued) ... 41
Table 4.4. Mechanical Line Competency Matrix ... 42
Table 4.4. Mechanical Line Competency Matrix (continued) ... 43
CHAPTER V – IMPLEMENTATION OF TRAINING CENTER ... 62
Table 5.1. Criteria and Value Scale ... 74
Table 5.2. Criteria and Value Scale for Application Navigation ... 74
Table 5.3. Criteria and Value Scale for Multimedia Aspects ... 75
Table 5.4. Criteria and Value Scale for Learning Materials ... 77
Table 5.5. Criteria and Value Scale for Learning Activity Aspects ... 79
Table 5.6. Criteria and Value Scale for Operational Aspects ... 81
